Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to the field of robotic surgical systems and, more particularly, to a surgical robotic surgical system for sterile transmission of mechanical motion.
BACKGROUND
[0002] Robotic surgical systems have revolutionized modern surgical procedures by enabling minimally invasive approaches with enhanced precision and control. The robotic surgical systems typically employ sophisticated robotic arms that manipulate specialized surgical instruments through small incisions in the patient's body. The success of such procedures heavily relies on the precise control and positioning of the specialized surgical instruments, which must operate with exceptional accuracy within confined anatomical spaces.
[0003] In the field of minimally invasive and robotic-assisted surgery, the requirements for precision, dexterity, and strict maintenance of sterility are critical to successful clinical outcomes. Robotic surgical systems enhance the capabilities of surgeons by enabling the use of highly articulated instruments capable of executing delicate and complex movements within confined anatomical spaces. The instruments depend on motor-driven actuators housed within the robotic system to generate controlled motion. To ensure accurate tool performance, the motion produced by the actuators must be transmitted to the surgical instruments with high fidelity while simultaneously preserving the integrity of the sterile barrier that isolates the patient from non-sterile components of the robotic system.
[0004] Conventional robotic surgical platforms typically employ intricate mechanical and electrical interfaces to link the actuator assemblies to the surgical instruments. For example, actuator mechanisms are embedded directly into reusable components, or sterility is maintained through external draping systems. The existing approaches, however, present notable limitations. Systems that integrate actuators into reusable structures necessitate rigorous and repeated sterilization procedures, which are resource-intensive and can degrade mechanical precision over time. Conversely, draping solutions often fail to fully isolate non-sterile elements or are prone to human error during setup, thereby increasing the risk of contamination. Furthermore, the conventional systems and techniques may result in mechanical misalignment, increased system complexity, and longer turnaround times between procedures, all of which negatively affect surgical workflow and patient safety.
[0005] Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks.
SUMMARY
[0006] The present disclosure provides a robotic surgical system. The present disclosure provides a solution to the technical problem of how to transmit controlled motion from the sterile actuator drive system to the sterile surgical instrument in a manner that ensures mechanical precision while preserving sterility during robotic-assisted surgical procedures. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art by incorporating a sterile adapter configured with mechanically interlocking couplers that form a modular and sterile interface between the actuator system and the surgical instrument. The configuration enables accurate and repeatable motion transfer through a dedicated sterile barrier, thereby improving surgical safety, reducing the risk of contamination, and streamlining the setup and maintenance of robotic surgical systems.
[0007] One or more objectives of the present disclosure is achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.
[0008] In one aspect, the present disclosure provides a robotic surgical system, comprising:
a patient-side cart comprising a robotic arm and an actuator drive system, the actuator drive system comprising a plurality of actuator couplers, each actuator coupler having at least two female engagement features;
a surgical instrument couplable to the robotic arm, the surgical instrument comprising:
an elongated shaft defining a longitudinal axis,
an end effector at a distal end of the elongated shaft, and
a plurality of instrument couplers at a proximal end of the surgical instrument,
each instrument coupler having at least two female engagement features and being operatively connected to the end effector; and
a sterile adapter positionable between the actuator drive system and the surgical instrument, the sterile adapter comprising a housing forming a sterile barrier and a plurality of sterile adapter couplers, each sterile adapter coupler having at least two male bottom engagement features that mechanically interlock with the at least two female engagement features of a corresponding actuator coupler and at least two male top engagement features that mechanically interlock with the at least two female engagement features of a corresponding instrument coupler,
wherein the mechanical interlocking of the at least two male bottom engagement features with the at least two female engagement features of each actuator coupler and the at least two male top engagement features with the at least two female engagement features of each instrument coupler creates a motion transfer path from the actuator drive system through the sterile adapter to the surgical instrument while the housing maintains sterility between the actuator drive system and the surgical instrument.
[0009] The robotic surgical system provides a precise, sterile, and modular mechanical coupling between the actuator drive system and the surgical instrument through the use of the sterile adapter. The arrangement of eliminates the need for direct contact between reusable actuators and sterilized instruments, thereby preserving the integrity of the sterile field throughout a surgical procedure. The sterile adapter includes a housing that acts as a dedicated sterile barrier, which is particularly in robotic assisted minimally invasive surgeries where any breach in sterility could compromise patient safety and procedural outcomes.
[0010] Each coupler includes at least two male bottom engagement features that mate with corresponding female engagement features on the actuator couplers, as well as at least two male top engagement features that engage with corresponding female features on the instrument couplers. The dual engagement structure enables the formation of a continuous, stable mechanical linkage from the actuator to the instrument. The use of multiple engagement features per coupler ensures distributed load transfer, reduces mechanical play, and enhances the precision and repeatability of motion transmission. By establishing a mechanically interlocked motion transfer path, the robotic surgical system ensures that high-fidelity movements generated by the actuator drive system such as rotation, oscillation, or linear displacement are accurately delivered to the end effector of the surgical instrument. The high-precision motion transfer is essential for delicate surgical manoeuvres, particularly in anatomically constrained or high-risk regions of the body.
[0011] Further, the sterile adapter may be assembled and disassembled independently of the actuator or instrument, which simplifies setup, reduces turnaround time between procedures, and allows for cost-effective reuse of the actuator components. The modular design also facilitates maintenance and inspection of individual components without compromising system-wide functionality. Furthermore, because the sterile adapter includes geometrically interlocking mechanical features such as asymmetrical locking mechanisms. The asymmetrical locking mechanisms ensure proper orientation and alignment, preventing misassembly and maintaining consistent performance across surgical sessions.
[0012] In an implementation, the plurality of sterile adapter couplers comprises at least four sterile adapter couplers arranged in a predetermined pattern within the housing. In such implementations, the arrangement of at least four sterile adapter couplers in a predetermined pattern within the housing provides uniform and balanced motion transfer from the actuator drive system to the surgical instrument. The configuration enhances mechanical stability, ensures consistent alignment, and allows precise multi-degree-of-freedom control of the instrument’s end effector during surgical procedures.
[0013] In another implementation, the sterile adapter further comprises a top cover having at least two asymmetrical male mechanical locking features configured to engage with at least two asymmetrical female mechanical locking features on the plurality of sterile adapter couplers to maintain a predefined orientation. In such implementations, the configuration of the sterile adapter eliminates the possibility of incorrect coupling between components of the robotic surgical system, thereby ensuring accurate alignment of the motion transmission path. The configuration of the sterile adapter enhances procedural safety, reduces assembly time, and prevents mechanical mismatches that could compromise instrument performance during surgery.
[0014] In yet another implementation, the motion transfer from the actuator drive system to the surgical instrument comprises rotational motion generated by motors in the actuator drive system. In such implementations, the rotational motion allows for efficient torque transmission, enabling smooth and accurate articulation of surgical tools. The accurate articulation enhances the surgeon’s ability to perform delicate manoeuvres with high repeatability and responsiveness, which is helpful in minimally invasive and robotic-assisted surgical procedures.
[0015] In yet another implementation, the at least two female engagement features of each instrument coupler are recessed within each instrument coupler to receive the corresponding at least two male top engagement features of each sterile adapter coupler. In such implementations, recessing the at least two female engagement features within each instrument coupler enhances the stability and alignment of the coupling interface with the corresponding male top engagement features of the sterile adapter coupler. The presence of at least two female engagement features of each instrument coupler design minimizes the risk of lateral displacement or disengagement during motion transmission, ensures a secure mechanical fit, and protects the engagement features from external contamination or damage. As a result, the minimized risk of lateral displacement or disengagement contributes to reliable motion transfer and maintains the overall integrity of the sterile connection.
[0016] In yet another implementation, the plurality of instrument couplers is operatively connected to a drive mechanism within the surgical instrument to actuate the end effector. In such implementations, connection of the plurality of instrument couplers to a drive mechanism within the surgical instrument provides the enables direct and efficient transmission of motion to the end effector. The configuration the plurality of instrument couplers and the drive mechanism ensures precise control over the functional tip of the surgical instrument, allowing for accurate articulation and responsiveness during surgical tasks, which is essential for performing complex minimally invasive procedures.
[0017] In yet another implementation, the drive mechanism comprises a plurality of drive elements that convert the motion received from each sterile adapter coupler into articulation of the end effector. In such implementations, the inclusion of the plurality of drive elements within the drive mechanism that convert the motion received from each sterile adapter coupler into articulation of the end effector provides enables independent and coordinated control of multiple degrees of freedom. The independent and coordinated control allows the end effector to perform complex and precise movements, enhancing surgical versatility and enabling delicate procedures in confined anatomical spaces with high accuracy and control.
[0018] In yet another implementation, the housing of the sterile adapter includes a proximal surface configured to interface with the actuator drive system. In such implementations, the proximal surface of the sterile adapter housing, configured to interface with the actuator drive system, creates a stable and sealed mechanical connection that supports efficient and secure motion transfer. The housing of the sterile adapter ensures proper alignment, minimizes assembly errors, and helps maintain the sterile barrier between the actuator system and the surgical field, thereby enhancing both functional reliability and infection control.
[0019] In yet another implementation, the housing of the sterile adapter further includes a distal surface configured to interface with the surgical instrument. In such implementations, the distal surface of the sterile adapter housing ensures precise alignment and secure engagement between the sterile adapter and the surgical instrument. The precise alignment and secure engagement facilitate accurate transmission of motion to the drive mechanism while maintaining the sterility of the interface, thereby supporting consistent surgical performance and reducing the risk of contamination.
[0020] In yet another implementation, the sterile adapter further includes at least one locking protrusion configured to engage with a corresponding locking recess of the surgical instrument. In such implementations, the inclusion of at least one locking protrusion on the sterile adapter, configured to engage with a corresponding locking recess on the surgical instrument, provides a mechanically secured interface that resists unintended disengagement during high-precision surgical manoeuvres. The locking protrusion ensures that the alignment between the sterile adapter and the surgical instrument is maintained under dynamic loading conditions, which is helps in preserving motion fidelity and system responsiveness.
[0021] In another aspect, the present disclosure provides a method for operating a robotic surgical system, the method comprising:
positioning a sterile adapter between an actuator drive system of a patient-side cart and a surgical instrument, wherein the sterile adapter comprises a housing forming a sterile barrier and a plurality of sterile adapter couplers;
mechanically interlocking at least two male bottom engagement features of each sterile adapter coupler with at least two female engagement features of a corresponding actuator coupler of a plurality of actuator couplers of the actuator drive system;
mechanically interlocking at least two male top engagement features of each sterile adapter coupler with at least two female engagement features of a corresponding instrument coupler of a plurality of instrument couplers of the surgical instrument, wherein the plurality of instrument couplers is located at a proximal end of the surgical instrument and are operatively connected to an end effector at a distal end of an elongated shaft of the surgical instrument;
creating a motion transfer path from the actuator drive system through the sterile adapter to the surgical instrument via the mechanical interlocking of the at least two male bottom engagement features with the at least two female engagement features of each actuator coupler and the at least two male top engagement features with the at least two female engagement features of the corresponding instrument coupler; and
transferring motion from the actuator drive system to the surgical instrument through the motion transfer path while the housing maintains sterility between the actuator drive system and the surgical instrument.
[0022] The method achieves all the advantages and technical effects of the robotic surgical system of the present disclosure.
[0023] It is to be appreciated that all the aforementioned implementation forms can be combined.
[0024] It has to be noted that all devices, elements, circuitry, units and means described in the present application could be implemented in the software or hardware elements or any kind of combination thereof. All steps which are performed by the various entities described in the present application as well as the functionalities described to be performed by the various entities are intended to mean that the respective entity is adapted to or configured to perform the respective steps and functionalities. Even if, in the following description of specific embodiments, a specific functionality or step to be performed by external entities is not reflected in the description of a specific detailed element of that entity which performs that specific step or functionality, it should be clear for a skilled person that these methods and functionalities can be implemented in respective software or hardware elements, or any kind of combination thereof. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
[0025] Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
[0027] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 is a diagram illustrating a robotic surgical system, in accordance with an embodiment of the present disclosure;
FIG. 2A is a diagram illustrating a surgical instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure;
FIG. 2B is a diagram illustrating a proximal end of the surgical instrument of the robotic surgical instrument, in accordance with an embodiment of the present disclosure;
FIG. 3 is a diagram illustrating an exploded view of engagement of an actuator drive system, a sterile adapter, and the surgical instrument with the proximal housing, in accordance with an embodiment of the present disclosure;
FIG. 4 is a diagram illustrating a top cover of the sterile adapter, in accordance with an embodiment of the present disclosure;
FIG. 5 is a diagram illustrating a bottom portion of the sterile adapter in accordance with an embodiment of the present disclosure;
FIG. 6 is a diagram illustrating an isometric view of an exemplary sterile adapter coupler, accordance with an embodiment of the present disclosure;
FIG. 7 is a diagram illustrating a top view of the exemplary sterile adapter coupler, accordance with an embodiment of the present disclosure;
FIG. 8 is a diagram illustrating a bottom view of the exemplary sterile adapter coupler, accordance with an embodiment of the present disclosure;
FIG. 9 is a diagram illustrating an engagement of the exemplary sterile adapter coupler with an exemplary actuator coupler, in accordance with an embodiment of the present disclosure;
FIG. 10 is a diagram illustrating the engagement of the exemplary sterile adapter coupler with an exemplary instrument coupler, in accordance with an embodiment of the present disclosure; and
FIG. 11 is a flowchart illustrating a method for operating the robotic surgical system, in accordance with an embodiment of the present disclosure.
[0028] In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
[0029] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
[0030] FIG. 1 is a diagram illustrating a robotic surgical system, in accordance with an embodiment of the present disclosure. With reference to FIG. 1, there is shown a robotic surgical system 100 including a patient-side cart 110, a vision cart 120, and a surgeon console 130.
[0031] The patient-side cart 110 is a mobile unit having a base mounted on wheels. The base includes locking mechanisms for securing the patient-side cart 110 in position. The patient-side cart 110 includes a vertical column extending upward from the base. The vertical column comprises a linear actuator enabling height adjustment. The patient-side cart 110 includes multiple robotic arms that extend from the vertical column. In some implementations, the multiple robotic arms include four robotic arms in which three robotic arms 112 are configured for surgical instrument manipulation and one robotic arm 113 is configured for endoscopic imaging. The robotic arms 112 include primary segments, secondary segments, and tertiary segments connected by rotational joints. The rotational joints contain servo motors enabling precise angular positioning. The robotic arms 112 include surgical instrument holders 114 at distal ends. The surgical instrument holders 114 comprise mechanical interfaces and electrical connectors. The mechanical interfaces include spring-loaded clamps for instrument attachment. The electrical connectors transmit power and signals to mounted instruments. The patient-side cart 110 further includes at least one surgical instrument 140 mounted to the surgical instrument holders 114 at one of the robotic arms 112. The surgical instrument includes elongated shafts with end effectors at distal tips. The end effectors include articulation mechanisms enabling pitch and yaw movements. The surgical instrument 140 includes internal drive cables connecting to motor units in the instrument holders. The drive cables actuate the end effector movements. The robotic arm 113 supports an endoscopic imaging system. Each of the robotic arms 112 includes additional degrees of freedom for camera positioning. The endoscopic imaging system includes dual high-definition camera sensors mounted at a distal end of the robotic arm 113. The dual camera sensors enable stereoscopic image capture. The endoscopic imaging system includes fibre optic light transmission bundles surrounding the camera sensors for illuminating the surgical field. The endoscopic imaging system enables both white light imaging and near-infrared fluorescence visualization. The endoscopic imaging system comprises glass rod lenses for controlling chromatic aberration and enhancing image quality.
[0032] The vision cart 120 is a mobile unit comprising a base with wheels and a vertical housing. The base contains power supply units and cooling systems. The vertical housing contains processing units and displays. The vertical housing includes ventilation channels for thermal management. The vision cart 120 includes a display 122 mounted at an upper portion of the vertical housing, wherein the display 122 comprises a high-definition LCD monitor with anti-glare coating. In some other embodiments, the vision cart 120 may include multiple displays. The vision cart 120 includes an electrosurgical unit (ESU) 124 mounted within the vertical housing. The vision cart 120 further includes endoscope light sources. The endoscope light sources comprise one or two light source units mounted within the vertical housing. The vision cart 120 includes an insufflator unit mounted within the vertical housing for creating and maintaining pneumoperitoneum. The vision cart 120 includes an uninterruptible power supply (UPS) system mounted within the base for providing backup power. The vision cart 120 further includes a video processing unit and a central processing unit within the vertical housing. The video processing unit includes dedicated graphics processors. The central processing unit comprises multiple processing cores. The vision cart 120 further includes data storage devices mounted within the vertical housing. In some implementations, the vision cart 120 comprises image enhancement processors for contrast adjustment and noise reduction. In some implementations, the vision cart 120 includes fluorescence imaging processors for tissue identification. In some implementations, the vision cart 120 includes augmented reality processors for data overlay generation.
[0033] The surgeon console 130 includes a base structure supporting an operator seat and control interfaces. The base structure includes levelling mechanisms for stable positioning. The operator seat comprises height adjustment mechanisms and lumbar support systems. A display housing extends upward and forward from the base structure. The display housing contains a stereoscopic display system 134. The stereoscopic display system 134 includes dual display panels and optical elements. The optical elements include focusing mechanisms and eye tracking sensors. The surgeon console 130 further includes master control manipulators 132 mounted on sides of the base structure in front of the operator seat. The master control manipulators 132 terminate in ergonomic hand grips. The hand grips contain pressure sensors and multi-function triggers. In some other embodiments, the hand grip provides haptic feedback. In some implementations, the surgeon console 130 further includes foot pedals mounted on a lower portion of the base structure. The foot pedals include position sensors and tactile feedback mechanisms. A user interface comprising touchscreens mounts on the base structure between the master control manipulators 132. The touchscreens display system status information and configuration controls.
[0034] The patient-side cart 110, the vision cart 120, and the surgeon console 130 connect through a communication network. The communication network comprises ethernet cables. In some other embodiments, the communication may be through any wireless communication protocol. The communication network includes redundant data pathways. The communication network transmits control signals from the master control manipulators 132 to the robotic arms 112. The control signals include position commands and gripper actuation commands. In some implementations, the communication network transmits imaging data from the endoscopic imaging system to the stereoscopic display system 134. The imaging data includes calibration parameters and camera position data. The robotic surgical system 100 includes monitoring systems connected to the communication network. The monitoring systems comprise voltage sensors, current sensors, temperature sensors, and position sensors.
[0035] In some implementations, the robotic surgical system 100 includes emergency stop mechanisms mounted on each component. The emergency stops mechanisms include physical switches and software-triggered stops. The robotic surgical system 100 includes power backup systems within each component. The power backup systems include batteries and uninterruptible power supplies. The robotic surgical system 100 includes fault detection processors within the vision cart 120. The fault detection processors monitor system parameters and component status.
[0036] In some implementations, the robotic surgical system 100 executes autonomous and semi-autonomous functions. In some implementations, the robotic surgical system 100 enables system upgrades through modular component replacement. The modular component replacement includes instrument interface upgrades and processing unit upgrades. The robotic surgical system 100 enables minimally invasive surgical procedures. Exemplary surgical procedures may include, but not limited to, general surgery procedures, gynaecological procedures, urological procedures, cardiothoracic procedures, and otolaryngological procedures.
[0037] FIG. 2A is a diagram illustrating an exemplary surgical instrument of the robotic surgical system, in accordance with an embodiment of the present disclosure. FIG. 2A is described in conjunction with the elements of FIG. 1. With reference to FIG. 2A, there is shown the surgical instrument 140 for use with the robotic surgical system 100 described in FIG. 1. The surgical instrument 140 comprises a proximal housing 200 and an end effector 210 connected by an elongated shaft 220. The proximal housing 200 includes a generally rectangular configuration with rounded edges for ergonomic handling. In some other implementations the proximal housing may have circular configuration. In yet another implementation, the proximal housing may have polygonal configuration. The proximal housing 200 comprises a top surface 230 having access apertures. The proximal housing 200 further includes side panels 232 with mounting fixtures positioned for secure attachment to actuators on the robotic arms 112. The proximal housing 200 contains internal drive mechanisms for actuating the end effector 210. In some implementations, the proximal housing 200 includes electronic components for receiving control signals from the robotic surgical system 100.
[0038] The proximal housing 200 comprises a circular coupling interface 234 located on a front face. The circular coupling interface 234 includes mechanical registration features ensuring precise alignment during instrument mounting. The circular coupling interface 234 is further configured to enable wireless signal transmission between the surgical instrument 140 and the robotic arm 112. The wireless signal transmission may be facilitated using one or more wireless communication technologies, including but not limited to radio-frequency identification (RFID), Bluetooth, infrared (IR), near-field communication (NFC), or any other suitable wireless protocol.
[0039] The proximal housing 200 comprises a circular coupling interface 234 located on a front face. The circular coupling interface 234 includes mechanical registration features configured to ensure precise alignment during instrument mounting. The circular coupling interface 234 is further configured to enable wireless signal transmission between the surgical instrument 140 and the robotic arm 112. The wireless signal transmission may be facilitated using one or more wireless communication technologies, including but not limited to radio-frequency identification (RFID), Bluetooth, infrared (IR), near-field communication (NFC), or any other suitable wireless protocol.
[0040] The elongated shaft 220 extends from the circular coupling interface 234 of the proximal housing 200. The elongated shaft 220 comprises a rigid cylindrical structure having a substantially uniform diameter. The elongated shaft 220 includes an outer sheath fabricated from biocompatible materials. The elongated shaft 220 contains internal drive cables, and mechanical linkages for transmitting forces and signals from the proximal housing 200 to the end effector 210. In some implementations, the elongated shaft 220 includes articulation segments comprising flexible joints or linkages, enabling multi-degree-of-freedom angular positioning and enhanced dexterity of the end effector 210. In some implementations, the elongated shaft 220 may be modular or detachable, allowing for easy replacement or sterilization. Additionally, in configurations utilizing wireless communication (e.g., RFID or other wireless protocols), internal wiring may be minimized or optimized for power delivery only, with control signals transmitted wirelessly from the proximal housing 200 to onboard controllers associated with the end effector 210.
[0041] The end effector 210 mounts to a distal end of the elongated shaft 220. The end effector 210 comprises a wrist mechanism 250 providing additional degrees of freedom. The wrist mechanism 250 includes articulation joints enabling pitch and yaw movements of grasping jaws 252. In some implementations, the wrist mechanism 250 contains gearing assemblies for converting linear actuation into rotational movement. The grasping jaws 252 include opposed members with tissue-interfacing surfaces. The tissue-interfacing surfaces comprise grip-enhancing textures for secure tissue manipulation. In some implementations, the grasping jaws 252 include integrated sensors for force feedback. In some implementations, the grasping jaws 252 incorporate electrosurgical elements for tissue coagulation.
[0042] The surgical instrument 140 includes mechanical registration features ensuring proper orientation when mounted to the robotic arm 112. The surgical instrument 140 comprises sealing elements preventing fluid ingress during surgical procedures. The surgical instrument 140 includes sterilization-compatible materials enabling repeated reprocessing cycles. In some implementations, the surgical instrument 140 comprises specialized end effectors for specific surgical tasks including tissue cutting, needle driving, clip application, and suturing. In some implementations, the surgical instrument 140 includes integrated cameras for additional visualization capabilities. The surgical instrument 140 operates under control of the surgeon console 130 via the robotic arm 112 to enable precise tissue manipulation during minimally invasive surgical procedures.
[0043] FIG. 2B is a diagram illustrating proximal end of the surgical instrument of the robotic surgical instrument, in accordance with an embodiment of the present disclosure. FIG. 2B is described in conjunction with the elements of FIGs. 1 and 2A. With reference to FIG. 2B, there is shown the surgical instrument 140. The surgical instrument 140 comprises a proximal housing 200 and an end effector 210 connected by an elongated shaft 220. The surgical instrument 140 includes a plurality of instrument couplers 256 (interchangeably referred to as plurality of instrument discs) at a proximal end 254. As illustrated in an embodiment of FIG. 2B, a first instrument coupler 256A, a second instrument coupler 256B, a third instrument coupler 256C and a fourth instrument coupler 256D. Further, each instrument coupler of the plurality of instrument couplers 256 includes at least two female engagement features. For example, as illustrated in embodiment of FIG. 2B, the first instrument coupler 256A includes a plurality of female engagement features 260, for example a first female engagement feature 260A and a second female engagement feature 260B. Similarly, the second instrument coupler 256B includes a plurality of female engagement features 262, i.e., a first female engagement feature 262A and a second female engagement feature 262B. Further, the third instrument coupler 256C includes a plurality of female engagement features 264. The at least two female engagement features of the plurality of instrument couplers 256 are operatively connected to the end effector 210.
[0044] FIG. 3 is a diagram illustrating an exploded view of the engagement of an actuator drive system, a sterile adapter, and the surgical instrument with the proximal housing, in accordance with an embodiment of the present disclosure. FIG. 3 is described in conjunction with the elements of FIGs. 1 to 2B. With reference to FIG. 3, there is shown an exploded view of the engagement of an actuator drive system 304, a sterile adapter 302 and the surgical instrument with the proximal housing 200. The sterile adapter 302 includes a housing with a drive interface on one side for connection to the actuator drive system 304. The drive interface is present on a bottom portion (not shown in FIG. 3) of the sterile adapter 302. The housing of the sterile adapter 302 further includes an instrument interface present on a top portion of the sterile adapter 302 for engaging with the surgical instrument 140 (shown in FIG. 2A and FIG. 2B). The sterile adapter 302 acts as an intermediary component that bridges the actuator drive system 304 and the surgical instrument 140. The sterile adapter 302 maintains a sterile barrier between the non-sterile (i.e., the actuator drive system 304) and sterile portions (i.e., the surgical instrument 140) of the robotic surgical system 100. Further, the sterile adapter 302 mechanically transfer motion from the plurality of actuator couplers to the surgical instrument 140. In some implementations, the housing structure includes alignment features and locking mechanisms that ensure precise positioning and secure attachment of the surgical instrument 140. The sterile adapter 302 includes a plurality of sterile adapter couplers 306. Each sterile adapter coupler of the plurality of sterile adapter couplers 306 includes at least two male top engagement present on the top portion of the sterile adapter 302 and at least two male bottom engagement features present on the bottom portion of the sterile adapter 302. For example, as illustrated in the embodiment of FIG. 3, the sterile adapter includes a first sterile adapter coupler 306A, a second sterile adapter coupler 306B, a third sterile adapter coupler 306C and a fourth sterile adapter coupler 306D. Each sterile adapter coupler includes at least two male top engagement features that mechanically interlock with at least two female engagement features of a corresponding instrument coupler. For example, as illustrated in the embodiment of FIG. 3, the second sterile adapter coupler 306B includes a plurality of male top engagement features 310, i.e., a first male top engagement feature 310A and a second male top engagement feature 310B. The first male top engagement feature 310A, engages with the first female engagement feature 262A and the first male top engagement feature 310A engages with the second female engagement feature 262B.
[0045] The surgical instrument 140 is configured to be removably coupled to the sterile adapter 302 through a plurality of engagement interfaces. The sterile adapter 302 acts as an intermediary connection mechanism between the surgical instrument 140 and the actuator drive system 304, facilitating sterile operation while enabling precise motion control and power transmission. The sterile adapter 302 includes specialized coupling mechanisms that maintain a sterile barrier while allowing mechanical power transmission between the actuator drive system 304 and the surgical instrument 140.
[0046] The actuator drive system 304 refers to a main motorized system that powers the surgical instrument 140 connected to the sterile adapter 302. In some implementations, the actuator drive system 304 refers to a system or mechanism that provides the power and control required to operate the surgical instrument 140, typically involving components such as motors, controllers, and transmission elements, often integrated with processors and memory for precise control and automation. The actuator drive system 304 includes a plurality of actuator couplers 308 (interchangeably referred to as actuator drives), each actuator coupler having at least two female engagement features that mechanically interlock with.the at least two male bottom engagement features (not shown in FIG. 3) of the each of the sterile adapter coupler. As illustrated in embodiment of the FIG. 3, a second actuator coupler 308B includes a plurality of female engagement features, for example a first female engagement features 312A and a second female engagement feature 312B. It is to be noted that the at least two male bottom engagement features are not shown in FIG. 3 due to illustration constraint.
[0047] FIG. 4 a diagram illustrating a top cover of the sterile adapter, in accordance with an embodiment of the present disclosure. FIG. 4 is described in conjunction with the elements of FIGs. 1 to 3. With reference to FIG. 4, there is shown a top cover 402 of the sterile adapter 302. In an implementation, the sterile adapter 302 further comprises the top cover 402 that includes a plurality of asymmetrical male mechanical locking features. Each sterile adapter coupler disposed within the sterile adapter 302 includes at least two asymmetrical female mechanical locking features (not shown in FIG. 4). For each asymmetrical female mechanical locking feature, the top cover 302 includes corresponding asymmetrical male mechanical locking features positioned to engage in a mechanically interlocking relationship. The plurality of asymmetrical male mechanical locking features is disposed on an internal surface of the top cover 402 and extend toward the plurality of sterile adapter couplers 306. The plurality of asymmetrical male mechanical locking features is non-uniform in geometry and spatial arrangement such that engagement is permitted only when the top cover 402 is oriented in a predetermined alignment relative to the underlying sterile adapter couplers. The engagement between the asymmetrical male mechanical locking features of the top cover 402 and the corresponding asymmetrical female mechanical locking features of each sterile adapter coupler ensures proper alignment and indexing of the plurality of adapter couplers 306 relative to the top cover 402. The configuration prevents rotational or mirrored misalignment during assembly and ensures that the motion transfer path between the actuator drive system 304 and the surgical instrument 140 is preserved with high positional accuracy. As illustrated in the embodiment of FIG. 4, the top cover 402 of the sterile adapter 302 include a first asymmetrical male mechanical locking feature 404 which engages with an asymmetrical female mechanical locking feature of the first sterile adapter coupler 306A. It is to be noted that, due to illustration constraints, the second asymmetrical male locking feature of the top cover is not shown in FIG. 4. Similarly, include a first asymmetrical male mechanical locking feature 406 which engages with an asymmetrical female mechanical locking feature (shown in FIG. 6) of the second sterile adapter coupler 306B, the top cover 402 further includes a first asymmetrical male mechanical locking feature 408 which engages with an asymmetrical female mechanical locking feature of the third sterile adapter coupler 306C and the top cover 402 further includes a first asymmetrical male mechanical locking feature 410 which engages with an asymmetrical female mechanical locking feature of the fourth sterile adapter coupler 306D.
[0048] FIG. 5 is a diagram illustrating a bottom portion of the sterile adapter in accordance with an embodiment of the present disclosure. FIG. 5 is described in conjunction with the elements of FIGs. 1 to 4. With reference to FIG. 5, there is shown a bottom portion of the sterile adapter 302. The sterile adapter 302 as explained in FIG. 3 includes the plurality of sterile adapter couplers 306. Each of the sterile adapter coupler includes at least two male bottom engagement features that mechanically interlock with the at least two female engagement features of a corresponding actuator coupler. As illustrated in embodiment of FIG. 5, the first sterile adapter coupler 306A includes two male bottom engagement features 502, i.e., a first male bottom engagement feature 502A and second male bottom engagement feature 502B.
[0049] Similarly, the second sterile adapter coupler 306B includes two male bottom engagement features 504, i.e., a first male bottom engagement feature 504A and a second male bottom engagement features 504B. Further, the third sterile adapter coupler 306C includes two male bottom engagement features 506, i.e., a first male bottom engagement feature 506A and a second male bottom engagement feature 506B. The fourth sterile adapter coupler 306D includes two male bottom engagement features 508, i.e., a first male bottom engagement feature 508A and second male bottom engagement features 508B.
[0050] FIG. 6 is a diagram illustrating an isometric view of an exemplary sterile adapter coupler, accordance with an embodiment of the present disclosure. FIG. 6 is described in conjunction with the elements of FIGs. 1 to 5. With reference to FIG. 6, there is shown an isometric view of an exemplary sterile adapter coupler. For example, as illustrated in an embodiment of the FIG. 6, the exemplary sterile adapter coupler is the second sterile adapter coupler 306B. The second sterile adapter coupler 306B includes the first male top engagement feature 310A and the second male top engagement feature 310B. Further, the second sterile adapter coupler 306B includes a first asymmetrical female mechanical locking feature 602. It is to be noted that a second asymmetrical female mechanical locking feature is not shown in FIG. 6 due to illustration constraint. In some other implementations, there may be more than two asymmetrical female mechanical locking features. The second sterile adapter coupler 306B also includes the second male bottom engagement feature 506B.
[0051] FIG. 7 is a diagram illustrating a top view of the exemplary sterile adapter coupler, accordance with an embodiment of the present disclosure. FIG. 7 is described in conjunction with the elements of FIGs. 1 to 6. With reference to FIG. 7, there is shown a top view of an exemplary sterile adapter coupler. For example, as illustrated in an embodiment of the FIG. 6, the exemplary sterile adapter coupler is the second sterile adapter coupler 306B. The second sterile adapter coupler 306B includes the first male top engagement feature 310A and the second male top engagement feature 310B. Further, the second sterile adapter coupler 306B includes the first asymmetrical female mechanical locking feature 602 and a second first asymmetrical female mechanical locking feature 702.
[0052] FIG. 8 is a diagram illustrating a bottom view of the exemplary sterile adapter coupler, accordance with an embodiment of the present disclosure. FIG. 8 is described in conjunction with the elements of FIGs. 1 to 7. With reference to FIG. 8, there is shown a bottom view of the exemplary sterile adapter coupler i.e., the second sterile adapter coupler 306B. The second sterile adapter coupler 306B includes the first male bottom engagement feature 504A and the second male bottom engagement feature 504B. Also, the second sterile adapter coupler 306B includes the first asymmetrical female mechanical locking feature 602 and the second first asymmetrical female mechanical locking feature 702.
[0053] FIG. 9 is an exemplary diagram illustrating an engagement of the exemplary sterile adapter coupler with an exemplary actuator coupler, in accordance with an embodiment of the present disclosure. FIG. 9 is described in conjunction with the elements of FIGs. 1 to 8. With reference to FIG. 9, there is shown interaction of the exemplary sterile adapter coupler (for example, as illustrated in an embodiment of the second sterile adapter coupler 306B with the second actuator coupler 308B).
[0054] The second sterile adapter coupler 306B is positioned above the second actuator coupler 308B in a pre-engagement configuration. The second sterile adapter coupler 306B comprises a cylindrical body with a flanged perimeter that forms part of the sterile barrier. On the bottom surface of the second sterile adapter coupler 306B, the second male bottom engagement feature 504B extends downward. The second male bottom engagement feature 504B is specifically configured to mechanically interlock with the first female engagement feature 312A of the second actuator coupler 308B. The second male bottom engagement feature 504B has precise dimensions and geometry that allow it to transmit rotational motion when engaged.
[0055] During the engagement process, the second sterile adapter coupler 306B is lowered onto the second actuator coupler 308B, aligning the second male bottom engagement feature 504B with the corresponding female engagement feature in the actuator coupler. As the second sterile adapter coupler 306B descends, the first male bottom engagement feature 504A inserts into the second female engagement feature 312B of the second actuator coupler 308B, creating a mechanical interlock that permits precise transfer of rotational motion from the second actuator coupler 308B to the second sterile adapter coupler 306B, while maintaining complete separation between the non-sterile actuator drive system and the sterile surgical field.
[0056] The specific design of the engagement features ensures robust mechanical coupling that eliminates backlash and ensures high-fidelity transmission of the precise movements required for delicate surgical procedures. The arrangement of multiple engagement features in a specific pattern further reinforces the system's reliability and precision during operation.
[0057] In operation, when the actuator drive system 304 activates, the actuator coupler for example, the second actuator coupler 308B rotates around its central axis. The rotational motion is precisely transferred to the second sterile adapter coupler 306B through the mechanical interlocking of the second male bottom engagement feature 504B with the corresponding female feature in the actuator coupler. The first asymmetrical female mechanical locking feature 602 engages with its corresponding male feature, ensuring that the components maintain proper alignment during rotation.
[0058] The second sterile adapter coupler 306B then rotates as a direct result of the actuator coupler's rotation, with minimal mechanical play or backlash due to the precision engineering of the engagement features. The rotational motion is subsequently transferred to the surgical instrument 140 through the male top engagement features on the upper surface of the second sterile adapter coupler 306B, which interlock with corresponding female features on the instrument coupler.
[0059] The specific design of these engagement features ensures robust mechanical coupling that eliminates backlash and ensures high-fidelity transmission of the precise movements required for delicate surgical procedures, all while maintaining a complete sterile barrier between the non-sterile actuator drive system and the sterile surgical instrument.
[0060] FIG. 10 is a diagram illustrating engagement of the exemplary sterile adapter coupler with an exemplary instrument coupler, in accordance with an embodiment of present disclosure. FIG. 10 is described in conjunction with the elements of FIGs. 1 to 9. With reference to FIG. 10, there is shown interaction of the exemplary sterile adapter coupler (i.e., the second sterile adapter coupler 306B) with an exemplary instrument coupler (i.e., the second instrument coupler 256B).
[0061] The engagement process between the second sterile adapter coupler 306B and the second instrument coupler 256B begins with proper positioning of the components relative to each other. As illustrated in FIG. 10, the second instrument coupler 256B having the second female engagement feature 262B. The second instrument coupler 256B is connected to the elongated shaft 220 of the surgical instrument 140 that extends upward and is positioned above the second sterile adapter coupler 306B. The first male top engagement feature 310A and the second male top engagement feature 310B of the second sterile adapter coupler 306B are oriented to align with corresponding female engagement features on the underside of the second instrument coupler 256B.
[0062] The surgeon aligns the second instrument coupler 256B such that its female engagement recesses (i.e., the recess of the second female engagement feature 262B) are positioned directly above the first male top engagement feature 310A and the second male top engagement features of the second sterile adapter coupler 306B. The distinctive asymmetrical pattern of these engagement features serves as a visual and tactile guide for proper orientation, with the first male top engagement feature 310A and the second male top engagement features of the second sterile adapter coupler 306B specifically positioned to match only the corresponding female recesses on the surgical instrument coupler when correctly aligned.
[0063] Once properly aligned, the second instrument coupler 256B is lowered toward the second sterile adapter coupler 306B. As this downward movement occurs, the first male top engagement feature 310A and the second male top engagement features of the second sterile adapter coupler 306B begin to enter the corresponding female engagement recesses of the instrument coupler. The specific geometry of the male engagement features, with their precisely engineered dimensions and possibly tapered leading edges, facilitates smooth initial entry and guides the components into proper position as they come together.
[0064] As the second instrument coupler 256B continues its downward movement, the male top engagement features of the sterile adapter the first male top engagement feature 310A and the second male top engagement features of the second sterile adapter coupler 306B coupler become fully inserted into the female engagement recesses of the instrument coupler. The dimensional tolerances between these complementary components are engineered with precision to create a secure mechanical interlock while still permitting free rotation of the coupled components. This precision engineering is essential for transferring rotational motion with minimal backlash or play, which directly impacts the surgeon's ability to perform delicate and precise manipulations with the end effector during surgical procedures. The additional mechanical interaction provides supplementary rotational indexing and helps ensure that proper alignment is maintained throughout the surgical procedure. When properly engaged, the components provide tactile and sometimes audible feedback to the operating room staff, confirming that correct and complete engagement has been achieved and that the system is ready for use.
[0065] During operational use, the rotational motion that has been transferred from the second actuator coupler 308B to the second sterile adapter coupler 306B (through the second male bottom engagement feature 504B) is now transmitted to the second instrument coupler 256B through the mechanical interlocking of the first male top engagement feature 310A and the second male top engagement feature 310B with the corresponding female features. As the second sterile adapter coupler 306B rotates under the influence of the actuator drive system 304, this rotational motion is directly transferred to the instrument coupler with high fidelity and precision. The instrument coupler, in turn, transmits this rotational motion through the elongated shaft to the drive mechanism housed within the surgical instrument.
[0066] The internal drive mechanism of the surgical instrument 140 then converts this rotational motion into the appropriate articulation movements of the end effector 212, enabling the precise surgical manipulations required for minimally invasive procedures. Throughout the entire process of motion transfer, the housing of the sterile adapter 302 maintains a complete sterile barrier between the actuator drive system 304 and the surgical instrument 140, thereby preserving the sterile field while allowing for the necessary transfer of mechanical motion required for surgical operation.
[0067] FIG. 11 is a flowchart illustrating a method for operating the robotic surgical system, in accordance with an embodiment of the present disclosure. FIG 11 is described in conjunction with elements from FIGs. 1 to 10. With reference to FIG. 11, there is shown a flowchart illustrating a method 1100 for operating the robotic surgical system 100. The method 1100 includes steps 1102 to 1110.
[0068] At step 1102, the method 1110 includes positioning the sterile adapter 302 between the actuator drive system 304 of the patient-side cart 110 and the surgical instrument 140. The sterile adapter 302 comprises a housing forming a sterile barrier and the plurality of sterile adapter couplers 306. The positioning of the sterile adapter 302 establishes a physical separation between the actuator drive system 304 and the sterile surgical instrument 140, creating a fundamental sterile barrier that prevents cross-contamination during surgical procedures. The strategic positioning enables subsequent mechanical connections while maintaining the integrity of the sterile field. The integrity of the sterile field is important for patient safety and infection control in minimally invasive robotic surgical procedures. The predetermined arrangement of the plurality of sterile adapter couplers 306 within the housing ensures proper alignment with both the actuator drive system 304 and the surgical instrument 140.
[0069] At step 1104, the method 1100 further includes mechanically interlocking at least two male bottom engagement features of each sterile adapter coupler with at least two female engagement features of the corresponding actuator coupler of the plurality of actuator couplers 308 of the actuator drive system 304. The mechanical interlocking creates a secure, zero-backlash connection between the actuator drive system 304 and the sterile adapter 302, enabling high-fidelity transmission of precise rotational movements. The use of at least two male bottom engagement features per sterile adapter coupler distributes mechanical forces evenly, reducing wear and increasing the operational lifespan of the components. The specific geometry of the male bottom engagement features and the at least two female engagement features of a corresponding actuator coupler ensures that they can only be assembled in the correct orientation, preventing misalignment that may compromise mechanical performance or sterility. The robust mechanical connection forms the first half of the motion transfer pathway while maintaining complete separation between non-sterile and sterile environments.
[0070] At step 1106, the method 1100 further includes mechanically interlocking at least two male top engagement features of each sterile adapter coupler with at least two female engagement features of the corresponding instrument coupler of the plurality of instrument couplers 310 of the surgical instrument 140. The plurality of instrument couplers 256 is located at the proximal end of the surgical instrument 140 and are operatively connected to the end effector at a distal end of an elongated shaft of the surgical instrument 140. The instrument interface completes the motion transfer pathway by establishing a secure connection between the sterile adapter 302 and the surgical instrument 140. The precise dimensional tolerances of the engagement features create a connection that transmits rotational motion with minimal mechanical play while still allowing for easy attachment and detachment during surgical setup and instrument changes. The dual engagement points provide redundancy and stability, ensuring consistent performance even under varying mechanical loads encountered during surgical manoeuvres. The connection maintains the sterile nature of the surgical instrument 140 while enabling it to receive precisely controlled movements from the actuator drive system 304.
[0071] At step 1108, the method 1100 further includes creating a motion transfer path from the actuator drive system 304 through the sterile adapter 302 to the surgical instrument 140 via the mechanical interlocking of the at least two male bottom engagement features with the at least two female engagement features of each actuator coupler and the at least two male top engagement features with the at least two female engagement features of the corresponding instrument coupler. The establishment of the complete motion transfer path enables seamless transmission of mechanical energy across the sterile barrier without compromising sterility. The multiple parallel motion transfer channels through the plurality of sterile adapter couplers 306 provide system redundancy and the capability for multi-degree-of-freedom control of the end effector 210 of the surgical instrument 140. The integrated mechanical linkage achieves high-precision motion transfer with minimal backlash, which is essential for the delicate and precise manipulations required in minimally invasive surgical procedures. The motion transfer path design eliminates the need for electrical or fluid connections across the sterile barrier, simplifying the interface and reducing potential points of sterility breach.
[0072] At step 1110, the method 1100 further includes transferring motion from the actuator drive system 304 to the surgical instrument 140 through the motion transfer path while the housing maintains sterility between the actuator drive system 304 and the surgical instrument 140. The high-fidelity transmission of rotational motion through the sterile adapter 302 ensures that surgeon inputs at the master control manipulators 132 are accurately replicated at a surgical site. Throughout the entire procedure, regardless of the complexity or duration of the operation, the housing of the sterile adapter 302 maintains a complete and uncompromised sterile barrier between the actuator drive system 304 and the surgical instrument 140. The continuous sterility maintenance eliminates the risk of contamination while allowing for the necessary transfer of mechanical motion required for effective surgical operation, thus enhancing patient safety without compromising surgical precision or control.
[0073] The steps 1102 to 1110 are only illustrative, and other alternatives can also be provided where one or more steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.
[0074] Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure.
, Claims:CLAIMS
We Claim:
1. A robotic surgical system (100) comprising:
a patient-side cart (110) comprising a robotic arm and an actuator drive system, the actuator drive system comprising a plurality of actuator couplers (308), each actuator coupler having at least two female engagement features;
a surgical instrument (140) couplable to the robotic arm, the surgical instrument (140) comprising: an elongated shaft (220) defining a longitudinal axis,
an end effector (210) at a distal end of the elongated shaft, and
a plurality of instrument couplers (256) at a proximal end (254) of the surgical instrument (140),
each instrument coupler having at least two female engagement features and being operatively connected to the end effector (210); and
a sterile adapter (302) positionable between the actuator drive system (304) and the surgical instrument (140), the sterile adapter (302) comprising a housing forming a sterile barrier and a plurality of sterile adapter couplers (306), each sterile adapter coupler having at least two male bottom engagement features that mechanically interlock with the at least two female engagement features of a corresponding actuator coupler and at least two male top engagement features that mechanically interlock with the at least two female engagement features of a corresponding instrument coupler,
wherein the mechanical interlocking of the at least two male bottom engagement features with the at least two female engagement features of each actuator coupler and the at least two male top engagement features with the at least two female engagement features of each instrument coupler creates a motion transfer path from the actuator drive system (304) through the sterile adapter (302) to the surgical instrument (140) while the housing maintains sterility between the actuator drive system (304) and the surgical instrument (140).
2. The robotic surgical system (100) as claimed in claim 1, wherein the plurality of sterile adapter couplers (306) comprises at least four sterile adapter couplers arranged in a predetermined pattern within the housing.
3. The robotic surgical system (100) as claimed in claim 1, wherein the sterile adapter (302) further comprises a top cover having at least two asymmetrical male mechanical locking features configured to engage with at least two asymmetrical female mechanical locking features on the plurality of sterile adapter couplers (306) to maintain a predefined orientation.
4. The robotic surgical system (100) as claimed in claim 1, wherein the motion transfer from the actuator drive system (304) to the surgical instrument (140) comprises rotational motion generated by motors in the actuator drive system (304).
5. The robotic surgical system (100) as claimed in claim 1, wherein the at least two female engagement features of each instrument coupler are recessed within each instrument coupler to receive the corresponding at least two male top engagement features of each sterile adapter coupler.
6. The robotic surgical system (100) as claimed in claim 1, wherein the plurality of instrument couplers (256) is operatively connected to a drive mechanism within the surgical instrument to actuate the end effector (210).
7. The robotic surgical system (100) as claimed in claim 6, wherein the drive mechanism comprises a plurality of drive elements that convert the motion received from each sterile adapter coupler into articulation of the end effector (210).
8. The robotic surgical system (100) as claimed in claim 1, wherein the housing of the sterile adapter (302) includes a proximal surface configured to interface with the actuator drive system (304).
9. The robotic surgical system (100) as claimed in claim 1, wherein the housing of the sterile adapter (302) further includes a distal surface configured to interface with the surgical instrument (140).
10. The robotic surgical system (100) as claimed in claim 1, wherein the sterile adapter (302) further includes at least one locking protrusion configured to engage with a corresponding locking recess of the surgical instrument (140).
11. A method (1110) for operating a robotic surgical system (100), the method (1110) comprising:
positioning a sterile adapter (302) between an actuator drive system (304) of a patient-side cart (110) and a surgical instrument (140), wherein the sterile adapter (302) comprises a housing forming a sterile barrier and a plurality of sterile adapter couplers (306);
mechanically interlocking at least two male bottom engagement features of each sterile adapter coupler with at least two female engagement features of a corresponding actuator coupler of a plurality of actuator couplers (308) of the actuator drive system (304);
mechanically interlocking at least two male top engagement features of each sterile adapter coupler with at least two female engagement features of a corresponding instrument coupler of a plurality of instrument couplers (310) of the surgical instrument (140), wherein the plurality of instrument couplers (256) is located at a proximal end of the surgical instrument and are operatively connected to an end effector at a distal end of an elongated shaft of the surgical instrument (140);
creating a motion transfer path from the actuator drive system (304) through the sterile adapter (302) to the surgical instrument (140) via the mechanical interlocking of the at least two male bottom engagement features with the at least two female engagement features of each actuator coupler and the at least two male top engagement features with the at least two female engagement features of the corresponding instrument coupler; and
transferring motion from the actuator drive system (304) to the surgical instrument (140) through the motion transfer path while the housing maintains sterility between the actuator drive system (304) and the surgical instrument (140).