CA2582053A1 - Integrated system for controlling plural surgical tools - Google Patents

Integrated system for controlling plural surgical tools Download PDF

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Publication number
CA2582053A1
CA2582053A1 CA002582053A CA2582053A CA2582053A1 CA 2582053 A1 CA2582053 A1 CA 2582053A1 CA 002582053 A CA002582053 A CA 002582053A CA 2582053 A CA2582053 A CA 2582053A CA 2582053 A1 CA2582053 A1 CA 2582053A1
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Canada
Prior art keywords
motor
handpiece
handpieces
winding
powered surgical
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Granted
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CA002582053A
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French (fr)
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CA2582053C (en
Inventor
Don Malackowski
Michael D. Dozeman
Paul M. Hoekstra
Michael R. Wildgen
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Stryker Corp
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Individual
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Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/16—Bone cutting, breaking or removal means other than saws, e.g. Osteoclasts; Drills or chisels for bones; Trepans
    • A61B17/1613—Component parts
    • A61B17/1626—Control means; Display units
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/32—Surgical cutting instruments
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/14—Surgical saws ; Accessories therefor
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/16—Bone cutting, breaking or removal means other than saws, e.g. Osteoclasts; Drills or chisels for bones; Trepans
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/16—Bone cutting, breaking or removal means other than saws, e.g. Osteoclasts; Drills or chisels for bones; Trepans
    • A61B17/1613—Component parts
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/16—Bone cutting, breaking or removal means other than saws, e.g. Osteoclasts; Drills or chisels for bones; Trepans
    • A61B17/1613—Component parts
    • A61B17/1622—Drill handpieces
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/16—Bone cutting, breaking or removal means other than saws, e.g. Osteoclasts; Drills or chisels for bones; Trepans
    • A61B17/1613—Component parts
    • A61B17/1628—Motors; Power supplies
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/32—Surgical cutting instruments
    • A61B17/320016—Endoscopic cutting instruments, e.g. arthroscopes, resectoscopes
    • A61B17/32002—Endoscopic cutting instruments, e.g. arthroscopes, resectoscopes with continuously rotating, oscillating or reciprocating cutting instruments
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B2017/00017—Electrical control of surgical instruments
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B2017/00017—Electrical control of surgical instruments
    • A61B2017/00199—Electrical control of surgical instruments with a console, e.g. a control panel with a display
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B2017/00367—Details of actuation of instruments, e.g. relations between pushing buttons, or the like, and activation of the tool, working tip, or the like
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
    • A61B2017/00973—Surgical instruments, devices or methods, e.g. tourniquets pedal-operated

Abstract

A surgical tool system including plural powered surgical handpieces. The handpieces are removably connected to a single control console. The control console has a power supply. A controller internal to the control console simultaneously supplies power to the plural handpieces. In the event the handpieces collectively draw more power than the power supply can provide, the control console temporarily stops the application of power to one of the handpieces.

Claims (56)

1. A control console (32) for energizing powered surgical handpieces (34), each handpiece having a power-consuming unit (36), said control console comprising:
a plurality of connectors (40), each connector configured to releaseably receive a separate handpiece so that plural handpieces are simultaneously connected to said control console;
a power regulator (86) for selectively energizing the handpieces through said connectors;
a controller (64) that controls said power supply to regulate the energization of the handpieces, characterized in that:
said controller and said power regulator are collectively configured so that said power regulator simultaneously energizes a plurality of handpieces.
2. The control console of Claim 1, wherein:
a power supply (90) supplies the power said power regulator (86) uses to energize the handpieces;
a power supply monitor (428) connected to said power supply to monitor power sourced by said power supply; and said power regulator (86) is further configured to, when said power supply monitor determines the power sourced by said power supply exceeds a threshold value, limit the application of power to one of the handpieces.
3. The control console of Claim 2, wherein said power regulator (86) is further configured to:
determine which of said handpieces drawing power is drawing the most power (430); and when said power supply monitor determines the power consumed by said power supply exceeds a threshold value, limit the application of power to the handpiece drawing the most power.
4. The control con sole of Claim 1, 2 or 3, wherein said power regulator (86) includes:
a plurality of drivers (210), each said driver configured to output a separate handpiece energization signal and to energize any of the attached handpieces, said plurality of drivers configured to simultaneously output plural energization signals; and a switch assembly (222) connected between said drivers and said connectors (40) so that the energization signal output by any one of said drivers can be output through any one of said connectors.
5. The control console of Claim 4, wherein:
there is a first plurality of said connectors (40) ;
and said power regulator (86) has a second plurality of said drivers (210), the plurality of drivers being less than the plurality of said connectors.
6. The control console of Claim 1, 2, 3, 4, or 5, wherein said power regulator is configured to apply energization signals to brushless DC motors (36) disposed in the handpieces (34).
7. The control console of Claim 1, 2, 3, 4, 5 or 6, wherein said connectors (40) are sockets configured to receive cables (38) that extend from the handpieces (34)
8. The control console of Claim 1, 2, 3, 4, 5, 6, or 7, wherein said controller (64) is further configured to:
read data in a memories (72) integral with the handpieces (34); and control the power supply based on the data read from the handpiece memories.
9. A system for energizing powered surgical handpieces (34), each handpiece having a power consuming unit (36), said system comprising:
a console (32) to which plural handpieces are attached;
a control assembly (64) disposed in said console for selectively applying energization signals to the handpiecs through said console;
a footswitch connected to said control assembly having at least switch that is actuated to generate a control signal to said control assembly in order to regulate the actuation of said handpieces, characterized in that a plurality of footswitches (44a, 44b) are connected to said control assembly for regulating the actuation of said handpieces.
10. The system for energizing powered surgical handpieces of Claim 9, wherein:
each of said footswitches (44a, 44b) is capable of generating control signals for regulating any one of the handpieces; and said control assembly (64), maps each said footswitch so that said footswitch controls at least one handpiece based on user-entered selection for that footswitch.
11. The system for energizing powered surgical handpieces of Claim 10, wherein:
said control assembly (64) monitors the number of handpieces (34) attached to said console (32) and the number of footswitches (44a, 44b) connected to said control assembly; and when said control assembly (64) determines that plural handpieces are attached to said console and plural said footswitches are connected to said control assembly, said control assembly forces a user to enter mapping instructions to indicate which said footswitch should be used to control which handpiece.
12. The system for energizing powered surgical handpieces of Claim 9, 10 or 11, wherein said control assembly is configured to allow plural said footswitches (44a, 44b) control a single handpiece (34).
13. The system for energizing powered surgical handpieces of Claim 12, wherein, said control assembly (64) is configured so that when plural said footswitches (44a, 44b) control a single handpiece (34) and a first footswitch generates a control signal that actuates the handpiece, said control assembly prevents a control signal generated by a second said footswitch from regulating the actuation of the handpiece until after the actuating control signals from both said footswitches are negated.
14. The system for energizing powered surgical handpieces of Claim 9, 10, 11, 12 or 13, wherein said control console, based on a control signal received from a first said footswitch, supplies an energization signal to a first handpiece and, simultaneously therewith, based on a control signal received from a second said footswitch, supplies an energization signal to a second said handpiece.
15. The system for energizing powered surgical handpiece of Claim 9, 10, 11, 12, 13 or 14, wherein, said control assembly is configured to apply energization signals to energize motors (36) internal to the handpieces.
16. The system for energizing powered surgical handpiece of Claim 9, 10, 11, 12, 13, 14 or 15, wherein said console is provided with a plurality of sockets (30), each said socket configured to releaseably receive a cable (38) attached to a handpiece (34).
17. The system for energizing powered surgical handpiece of Claim 9, 10, 11, 12, 13, 14, 15 or 16 ,wherein said control assembly (64) is further configured to:
read data in a memories (72) integral with the handieces (34); and apply the energization signals to the handpieces based on the data read from the handpiece memories.
18. A powered surgical tool system comprising:
a surgical handpiece (34) for receiving a cutting accessory (35), said surgical handpiece including a brushless, sensorless motor (36) with a plurality of windings (234) for actuating the accessory;
a driver for selectively applying energization signals to said motor windings based on back electromotive force signals produced across said windings, characterized in that:
said driver is configured to:
when the motor speed is above a threshold rate, selectively apply the energization signals to said motor windings based on back electromotive force sensing of rotor position; and when the motor speed is at or below the threshold rate, selectively apply the energization signals to said motor windings based on inductance sensing of motor rotor position.
19. The powered surgical tool system of Claim 18, wherein said driver, when performing inductance sensing of motor rotor position is configured to:
measure the current flow through each winding; and normalize the plurality of winding current flow measurements.
20. The powered surgical tool system of Claims 18 or 19, wherein said driver, when performing inductance sensing of motor rotor position is configured to:
measure current flow through each said winding;

determine through which winding there is the greatest current flow;
based on the winding through which there is the greatest current flow, determine rotor position.
21. The powered surgical tool system of Claims 18 or 19, wherein said driver, when performing inductance sensing of motor rotor position is configured to:
measure current flow through each said winding;
compare the measured winding current flows to a model of winding current flows; and based on the comparison of the measured winding current flows to the model of winding current flows, determine rotor position.
22. The powered surgical tool system of Claims 18, 19 20 or 21, wherein said driver is configured to perform inductance sensing of motor rotor position at motor start up.
23. A method of applying energization signals to a powered surgical tool (34) having a brushless, sensorless motor (36) having a plurality of windings (234), including the steps of:
determining the position of the motor rotor; and based on the position of the motor rotor, applying energization signals to selected motor windings, characterized in that, in said step of determining the position of the motor rotor, inductance sensing is used to determine motor rotor position.
24. The method of applying energization signals to a powered surgical tool of Claim 23, wherein:
the inductance of each motor winding is measured;
the winding inductance measurements are, normalized;
and the normalized winding inductance measurements are used to determine motor rotor position.
25. The method of applying energization signals to a powered surgical tool of Claim 24, where:
the winding inductance measurements are normalized by selective multiplication or offset adjustment of the measured inductances; and during operation of the motor, the gain or offset values used to normalize the winding inductance measurements are adjusted.
26. The method of applying energization signals to a powered surgical tool of Claims 24 or 25, wherein gain or offset values for normalizing the winding inductance measurements are read from a memory (72) integral with the surgical tool.
27. The method of applying energization signals to a powered surgical tool of Claim 23, 24, 25 or 26, wherein:
current flow through each winding is measured;
the winding through which winding there is the largest current flow is determined; and based on through which winding there is the largest current flow, rotor position is determined.
28. The method of applying energization signals to a powered surgical tool of Claim 27, wherein:
after the winding through which there is the largest current flow is determined, there is a determination if the winding current flow measurements are erroneous; and if it is determined that the winding current flow measurements are erroneous, said step of determining motor rotor position is omitted.
29. The method of applying energization signals to a powered surgical tool of Claim 28, wherein said process of determining if the winding current flow measurements are erroneous is performed by:
when the motor rotor is in a given first position, determining an expected second position of the rotor;
based on the expected second position of the motor rotor, determining the expected next winding through which there should be the largest current flow ;
if, in said step of determining through which winding there is the current flow, it is determined that the largest current flow is through the expected next winding, accepting the current flow measurements as correct (352, 354); and if, in said step of determining through which winding there is the current flow, it is determined that the largest current flow is not through the expected next winding and the measurement is below a cutoff value, accepting that the current flow measurements are erroneous (356).
30. The method of applying energization signals to a powered surgical tool of Claim 23, 24, 25, or 26, wherein:

current flow through each winding is measured (378);
the measured winding current flows are compared to a model of winding current flows (380); and based on the comparison of the measured winding current flows to the model of winding current flows, determining rotor position.
31. The method of applying energization signals to a powered surgical tool of Claim 23, 24, 25, 26, 27, 28, 29 or 30, wherein said step of using inductance sensing to determining motor rotor position is used when at motor start up.
32. The method of applying energization signals to a powered surgical tool of Claim 23, 24, 25, 26, 27, 28, 29, 30 or 31, wherein:
said step of using inductance sensing to determine motor rotor position is used when the motor rotor is at or below a threshold speed; and above the threshold speed, alternative means are used to determine motor rotor position.
33. The method of applying energization signals to a powered surgical tool of Claim 32, wherein the threshold speed is 10% or less of the maximum motor speed.
34. A method of applying energization signals to a powered surgical tool (34) having a brushless, sensorless motor (36) having a plurality of windings (234), including the steps of:

determining the position of the motor rotor based on the monitoring of the back electromotive forces across the windings; and based on the position of the motor rotor, applying energization signal to selected motor windings, characterized in that, in said step of monitoring the back electromotive forces across the windings, the monitoring compensates for flyback currents through the windings.
35. The method of applying energization signals to a powered surgical tool of Claim 34, wherein said back electromotive force monitoring is performed by integrating the back electromotive force signal across a winding from start time that begins at a select time after the initial rise or fall of the signal.
36. The method of applying energization signals to a powered surgical tool of Claim 35, wherein the start times at which the back electromotive force signals are integrated are adjusted in real time as a function of rotor speed.
37. The method of applying energization signals to a powered surgical tool of Claim 35, 36 or 37, wherein each back electromotive force signal is integrated until a threshold value is reached.
38. The method of applying energization signals to a powered surgical tool of Claim 37, wherein the integration threshold value is obtained from data read from a memory (62) integral with the surgical tool.
39. A system for energizing powered surgical handpieces (34), each handpiece having a power consuming unit (36) and at least one internal device that outputs o r receives signals, said system comprising:
a console (32) to which plural handpieces are attached;
a control assembly (64) disposed in said console for selectively applying energization signals to the handpieces through said console;
an interface (70) disposed in said console for connection to the handpiece internal device, characterized in that:
said interface (70) is configured to, over a single communications line, transmit to or receive from the handpiece internal device either digital or analog signals.
40. The system for energizing powered surgical handpieces of Claim 30, wherein said interface has:
an analog to digital converter, (472) for receiving signals from the handpiece internal device and converting received analog signals into digital signals; and a controller (470) said control configured to disable said analog to digital converter when digital signals are received from the handpiece internal device.
41. A control console for simultaneously energizing plural surgical handpieces as described in the above specification and illustrated in the accompanying drawings.
42. A system for energizing at least one powered surgical handpiece including a console (32) to which a plurality of footswitches (44a, 44b) are attached such that each footswitch can be used to control the actuation of the at least one surgical handpiece as described in the above specification and illustrated in the accompanying drawings.
43. A method of regulating the application of energization signals to a surgical handpiece having a brushless, sensorless DC motor as described in the above specification and illustrated in the accompanying drawings.
44. A method of regulating the application of energization signals to surgical handpiece having a brushless, sensorless DC motor using inductance sensing of motor rotor position as described in the above specification and illustrated in the accompanying drawings.
45. The method of regulating the application of energization signals to surgical handpiece of Claim 45, wherein:
based on the inductance sensed-determination of motor rotor position, motor rotor speed is determined;
and based on motor rotor speed, the application of the energization signals to the motor is controlled to cause the motor rotor to rotate at a desired speed.
46. A method of regulating the application of energization signals to a surgical handpiece having a brushless, sensorless DC motor using back electromotive force sensing of motor rotor position as described in the above specification and illustrated in the accompanying drawings.
47. A method of regulating the application of energization signals to a surgical handpiece (34) to which a cutting accessory (35) is attached, said surgical handpiece including a brushless, sensorless motor (36) said method including the steps of:
determining the position of the rotor internal to the motor; and based on the position of the motor rotor applying energization signals to windings (234) of the motor;
characterized in that, said step of determining the position of the motor rotor and said step of applying energization signals to the motor winding based on rotor position are performed from motor stall (0 RPM) to a motor maximum speed.
48. The method of regulating the application of energization signals to a surgical handpiece (34) wherein:
below a threshold speed a first method is used to determine motor rotor position; and at or above the threshold speed a second method is used to determine motor rotor position.
49. A method of oscillating the motor (36) of a surgical handpiece (36), the handpiece having a cutting accessory (35) that is oscillated by the motor, said method including the steps of:
actuating the handpiece motor so that the motor rotor turns for a set number of rotations in a first direction, and reversing the rotation of the motor rotor so that the rotor turns the set number of rotations in a second direction, characterized in that, a determination is made of the turn time it should take the handpiece motor to turn in the set number of rotations;
during the actuation of the handpiece motor, monitoring the time it takes to turn the set number of rotations;
comparing the the time it takes the actuated motor to make the set number of rotations to the determined turn time; and if the time the handpiece motor takes to turn the set number of rotations exceeds the turn time, reversing the rotation of the handpiece motor.
50. The method of oscillating the motor (36) of a surgical handpiece (36) of Claim 49, wherein:
generating a compensated turn time for the handpiece motor rotor based on the determined turn time, the compensated turn time being greater than the determined turn time; and in said step of comparing the time it take the actuated motor to make the set number of rotations, the comparison is made to the compensated turn time; and if the time the handpiece motor takes to turn the set number of rotations exceeds the compensated time, reversing the rotation of the handpiece motor.
51. The method of oscillating the motor (36) of a surgical handpiece (36) of Claim 50, wherein said compensated turn time is generated by multipling the determined turn time by a constant.
52. The method of oscillating the motor 36) of a surgical handpiece (36) of Claim 49, 50 or 51, wherein said handpiece is attached to a control console (32).
53. A method of actuating a powered surgical handpiece (34), with a control console (32) said method including the steps of:
transmitting instructions to a control console for regulating the actuation of the surgical handpiece over a wireless communications link;
based on the received instructions, the console supplies an energization signal to the handpiece to actuate the handpiece;
characterized in that:
the control console continually determines the elapsed time between when instructions are received over the communications link (816); and if the elapsed time after one instruction is received and before a next instruction is received exceeds a cutoff time, the control console deactivates the handpiece (818, 820).
54. A method of determining if a surgical handpiece (34) or a surgical cutting accessory (35) remains attached to a control console (32), the device or the cutting accessory having a data storage component, said method comprising the steps of:
forwarding a ping inquiry to the component internal to the handpiece or cutting accessory from the control console; and determining if a ping response is received by the control console (862), characterized in that:
if a ping response is not received by the control console, determining if appreciable ambient RF or EM
noise is present (864); and if ambient RF or EM noise is not present, assuming the handpiece or cutting accessory is disconnected from the control console (866).
55. The method of determining if a surgical handpiece (34) or a surgical cutting accessory (35) remains attached to a control console(32) of Claim 56, wherein said step of determining if appreciable ambient RF or EM noise is present according to the methods described above and illustrated in the attached drawings.
56. A method of actuating a motor (36) of a surgical handpiece (34), the handpiece having a cutting accessory (35) actuated by the motor, said method including:
generating a speed set point signal at which the motor should be run applying an energization signal to the motor to cause the motor to run at at the set speed is to be run;
and when the speed set point signal indicates the motor is to be stopped, applying braking signals to deaccelerate the motor, characterized in that:
comparing the speed set point to the motor actual speed;
and when the comparison indicates the motor actual speed is above the set point speed and the set point speed is above zero speed (0 RPM) selectively applying braking signals to deaccelerate the motor to the set point speed.
CA2582053A 2004-09-29 2005-09-28 Integrated system for controlling plural surgical tools Active CA2582053C (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US61408904P 2004-09-29 2004-09-29
US60/614,089 2004-09-29
US10/955,381 2004-09-30
US10/955,381 US7422582B2 (en) 2004-09-29 2004-09-30 Control console to which powered surgical handpieces are connected, the console configured to simultaneously energize more than one and less than all of the handpieces
PCT/US2005/034800 WO2006039331A2 (en) 2004-09-29 2005-09-28 Integrated system for controlling plural surgical tools

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CA2582053A1 true CA2582053A1 (en) 2006-04-13
CA2582053C CA2582053C (en) 2013-11-12

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US (4) US7422582B2 (en)
EP (2) EP2335616B1 (en)
JP (1) JP2008514367A (en)
KR (1) KR101406657B1 (en)
AU (1) AU2005292140B8 (en)
CA (1) CA2582053C (en)
DE (1) DE602005027091D1 (en)
WO (1) WO2006039331A2 (en)

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