Design and Validation of an Automatic Instrument Carousel Exchange System (ICES) for Robotic Surgery with Modular Instruments

Background Efficient and safe instrument exchange remains an important challenge in robotic minimally invasive surgery. Current workflows require human assistance, increasing staff workload and contamination risk. The modular design of the AdLap robotic laparoscopic instruments enables automated exchange of instrument shafts. This study presents the development and validation of the Instrument Carousel Exchange System (ICES). Methods An automatic ICES was developed for the AdLap robotic surgery platform. The prototype was designed to hold six Shaft-Actuated Tip-Articulating (SATA) modular instrument shafts and focused on compactness, robustness, modularity, and rapid disassembly for cleaning and sterilization. System performance was evaluated using repeated autonomous instrument exchange cycles without user interaction. Reliability, alignment tolerance, safety, and exchange duration were assessed. Results The ICES prototype was successfully designed, manufactured, and tested. Repeated functional testing demonstrated reliable autonomous instrument shaft exchange without human intervention. The system tolerated minor alignment deviations while maintaining stable and safe operation. Mean time for a complete instrument shaft exchange was 84 seconds (SD = 10 seconds). The modular architecture allowed straightforward disassembly and maintenance while preserving structural integrity and compact design. Conclusions The developed ICES represents a substantial step toward fully automated robotic modular instrument handling in minimally invasive surgery. Automated instrument exchange may reduce staff workload and minimize contamination risk during robotic procedures. Future work will focus on improving automation speed, alignment efficiency, and autonomous reinsertion of the instrument shaft through the trocar to further enhance clinical applicability.