A system comprising: a robot comprising an arm having an attachment and, for each of n joints, a driver and a joint sensor; and a control unit configured to: obtain a desired position of the attachment; for each of k<n joints, obtain a sensed joint state; compare the states to a set of criteria indicative of the arm moving from a first to a second configuration; the states matching the set of criteria, determine a magnitude of an adjustment signal configured to slow, halt or reverse movement of the arm towards the second configuration; using the desired position of the attachment and the states, determine a direction of the adjustment signal; for each of the n joints, obtain a sensed joint state; using the desired position of the attachment, the obtained n states and the adjustment signal, determine signals for controlling the drivers; and drive the joints using the signals.

A method of engaging a medical instrument with a medical instrument manipulator comprises receiving an indication that a first input coupling of the medical instrument is positioned adjacent to a first drive output of the manipulator. The first drive output is driven by a first actuating element. In response to receiving the indication, the first drive output is rotated in a first rotational direction. A determination is made, by one or more processors, as to whether a resistance torque is experienced by the first actuating element after rotating the first drive output in the first rotational direction. If the resistance torque is not experienced by the first actuating element after rotating of the first drive output in the first rotational direction, the first drive output is rotated in a second rotational direction. A determination is made, by the one or more processors, as to whether a resistance torque is experienced by the first actuating element after rotating of the first drive output in the second rotational direction.

User-initiated break-away clutching includes a robotic system having a joint, a brake or drive unit coupled to the joint, and a control system coupled with the brake or drive unit. The control system is configured to determine a first manual effort applied to the joint; inhibit, using the brake or drive unit, manual articulation of the joint in response to the first manual effort being below an articulation threshold; facilitate, using the brake or drive unit, the manual articulation of the joint in response to the first manual effort exceeding the articulation threshold; and inhibit, using the brake or drive unit, further manual articulation of the joint in response to a determination that a speed of the manual articulation of the joint is below a speed threshold.

A system and method for determining a patient force during a motion includes a tether adapted to be biased during a motion so that a tension force is applied. The tether is connected a motor and generates a tether force about the motor. The system controls the motor by generating a motor torque in a direction opposite the tether force. A recording module stores the motor torque at a plurality of intervals during the motion and a position of the tether. A display module generates a plot of a position of the patient versus a force generated by the patient. The position of the patient corresponds to the cumulative rotation of the shaft in the first direction about the axis of rotation of the shaft at each of the intervals. The force generated by the patient corresponds to the amount of motor torque at each of the intervals.

The surgical robotic system includes a robotic arm having one or more joints, each having a motor and at least one torque sensor and a velocity sensor. The system also includes a main controller, which outputs a drive command to the motor thereby actuating the motor. The system further includes a safety observer, which receives a measured velocity of the motor from the sensor, calculates an observed velocity, and detects a failure in operation of the at least one joint based on the observed velocity and the measured velocity.

A surgical system includes a control circuit, a surgical instrument, and a user interface is disclosed. The surgical instrument includes a plurality of components and a sensor. Each of the plurality of components of the surgical instrument includes a device parameter and is configured to transmit its respective device parameter to the control circuit. The sensor of the surgical instrument is configured to detect a tissue parameter associated with a proposed function of the surgical instrument, and transmit the detected tissue parameter to the control circuit. The control circuit is configured to analyze the detected tissue parameter in cooperation with each respective device parameter based on a system-defined constraint. The user interface is configured to indicate whether the surgical instrument comprising the plurality of components is appropriate to perform the proposed function.

A method for producing a surgical instrument is disclosed. The method comprises obtaining a handle, wherein the handle comprises a distal end comprising a shaft interface surface and a first set of magnetic elements. The method further comprises obtaining a shaft, wherein the shaft comprises a proximal end comprising a handle interface surface, a second set of magnetic elements, and a third set of magnetic elements. The method further comprises attaching the shaft to the handle, wherein the shaft interface surface is configured to engage the shaft at the handle interface surface, wherein an attractive magnetic force is configured to pull the handle towards the shaft when the first set of magnetic elements interact with the second magnetic elements, and wherein a repulsive magnetic force is configured to repel the handle from the shaft when the first set of magnetic elements interacts with the third set of magnetic elements.

Various torque-limiting screwdriver devices, systems, and methods are disclosed. The screwdriver can include a body, a motor that is configured to rotate a screw engaged with the screwdriver, and a processor configured to control operation of the screwdriver. The screwdriver can have torque-limiting functionality, such as by monitoring the amount of torque applied to the screw and reducing or stopping rotation of the screw when certain torque-limiting criteria are met. In some embodiments, the screwdriver can be switched between manual operation by a user, and automated operation by a motor within the screwdriver. In some embodiments, the screwdriver can be attached to a robotic arm.

A surgical robotic component comprising an articulated terminal portion, the terminal portion comprising: a distal segment having an attachment connected thereto, an intermediate segment, and a basal segment whereby the terminal portion is attached to the remainder of the surgical robotic component. The terminal portion further comprises a first articulation between the distal segment and the intermediate segment, the first articulation permitting relative rotation of the distal segment and the intermediate segment about a first axis, and a second articulation between the intermediate segment and the basal segment, the second articulation permitting relative rotation of the intermediate segment and the basal segment about a second axis. The intermediate segment comprises: a third articulation permitting relative rotation of the distal segment and the basal segment about third and fourth axes, a first torque sensor configured to sense torque about the third axis, and a second torque sensor configured to sense torque about the fourth axis. The first, second and third articulations are arranged such that in at least one configuration of the third articulation the first and second axes are parallel and the third and fourth axes are transverse to the first axis.

A computer-assisted device include an actuator and one or more processors. The computer-assisted device is configured to support an instrument having an end effector located at a distal end. To perform an operation with the instrument, the one or more processors are configured to operate the end effector according to a state machine having a first state and a second state. In the first state a velocity set point of the actuator is set to a first velocity. In the second state the velocity set point of the actuator is set to a second velocity lower than the first velocity. The state machine transitions from the first state to the second state when a force or torque applied by the actuator is above a first threshold and transitions from the second state to the first state when the force or torque applied by the actuator is below a second threshold.