U.S. patent application number 09/789040 was filed with the patent office on 2001-07-12 for system for controlling a motor driven surgical cutting instrument.
This patent application is currently assigned to PROMEX, INC.. Invention is credited to Henry, Daniel John, Kara, Miklos T., Mark, Joseph L., McCary, Brian, Miller, Michael E..
Application Number | 20010007944 09/789040 |
Document ID | / |
Family ID | 22639725 |
Filed Date | 2001-07-12 |
United States Patent
Application |
20010007944 |
Kind Code |
A1 |
Mark, Joseph L. ; et
al. |
July 12, 2001 |
System for controlling a motor driven surgical cutting
instrument
Abstract
A system is provided for controlling the stopping position of a
surgical cutting tool relative to a tissue entrance location of a
cannula housing the cutting tool. A signal processor is responsive
to a motor activation signal to provide a motor activation signal
to a motor control unit for driving a motor, which activates the
cutting tool positioned in a cannula. The signal processor is
responsive to a motor stop signal and to a stop position signal to
stop the cutting tool relative to the tissue entrance location of
the cannula to thereby avoid trapping a portion of the tissue base
between the cutting tool and a boundary of the cannula opening.
Inventors: |
Mark, Joseph L.;
(Indianapolis, IN) ; Miller, Michael E.;
(Trafalgar, IN) ; Kara, Miklos T.; (Indianapolis,
IN) ; Henry, Daniel John; (Winchester, VA) ;
McCary, Brian; (St. Louis, MO) |
Correspondence
Address: |
Michael D. Beck
BAKER & DANIELS
Suite 2700
300 N. Meridian St.
Indianapolis
IN
46204
US
|
Assignee: |
PROMEX, INC.
|
Family ID: |
22639725 |
Appl. No.: |
09/789040 |
Filed: |
February 20, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
09789040 |
Feb 20, 2001 |
|
|
|
09175293 |
Oct 20, 1998 |
|
|
|
Current U.S.
Class: |
606/170 |
Current CPC
Class: |
A61B 17/32002 20130101;
A61B 2017/00017 20130101; A61B 2017/00039 20130101 |
Class at
Publication: |
606/170 |
International
Class: |
A61B 017/32 |
Claims
What is claimed is:
1. A tissue cutting apparatus comprising: an elongated housing
configured for insertion into a body site, said housing having a
first end defining an opening adjacent thereto; a tissue cutting
tool disposed within said housing and defining at least one cutting
surface configured for movement relative to said housing adjacent
said opening to thereby excise tissue extending into said opening;
a motor driving a drive shaft extending therefrom and coupled to
said cutting tool, said motor operable to drive said cutting tool
at a cutting speed to excise tissue at said opening; means for
sensing a predefined position of said drive shaft relative to said
housing and producing a stop position signal corresponding thereto,
said predefined position corresponding to a position of said at
least one cutting surface relative to said opening to avoid
trapping unexcised tissue therebetween; means for generating a
motor stop signal when it is desired to stop said cutting tool; and
a control circuit responsive to said motor stop signal to
deactivate said motor with said drive shaft at a position prior to
said predefined position so that said motor stops with said drive
shaft substantially at said predefined position.
2. The tissue cutting apparatus of claim 1, wherein said motor is a
brushed DC motor.
3. The tissue cutting apparatus of claim 1 wherein said motor is
responsive to a motor activation signal provided by said control
circuit to rotationally drive said drive shaft.
4. The tissue cutting apparatus of claim 3 wherein said drive shaft
is connected to said cutting tool to thereby drive said cutting
tool rotationally about a longitudinal axis defined by said
elongated housing.
5. The tissue cutting apparatus of claim 3 further including
transmission means disposed between said motor and said cutting
tool for converting rotary motion from said rotating drive shaft to
reciprocating linear motion of said cutting tool to thereby drive
said cutting tool in a linearly reciprocating fashion relative to a
longitudinal axis defined by said elongated housing.
6. The tissue cutting apparatus of claim 3 wherein said means for
sensing a predefined position of said drive shaft relative to said
housing includes: a mark associated with said drive shaft; and a
sensor operable to sense passage thereby of said mark and produce
said stop position signal.
7. The tissue cutting apparatus of claim 6 wherein said mark is a
magnetized identifier attached to said drive shaft.
8. The tissue cutting apparatus of claim 7, wherein said sensor is
a Hall effect sensor attached to said housing.
9. The tissue cutting apparatus of claim 3 wherein: said motor
activation signal is a variable motor speed signal; and further
including a motor control circuit disposed between said control
circuit and said motor, said motor control circuit responsive to
said variable motor speed signal to drive said motor at a
corresponding rotational speed.
10. The tissue cutting apparatus of claim 9, wherein said motor
control circuit includes: a power amplifier providing a current
signal to said motor; and a current sensor sensing the current
provided to said motor and providing a current feedback to said
power amplifier, whereby said power amplifier is responsive to said
current feedback to control the current signal provided to said
motor.
11. The tissue cutting apparatus of claim 10, wherein said motor
control circuit includes a switch disposed between said current
sensor and said power amplifier operable to disable said current
feedback in response to said motor stop signal.
12. The tissue cutting apparatus of claim 9 wherein said motor
control circuit includes: a pulse width modulation (PWM) signal
generator responsive to said motor speed signal to produce a
corresponding PWM signal; and a motor driver circuit responsive to
said PWM signal to drive said motor at a corresponding rotational
speed.
13. The tissue cutting apparatus of claim 1 further including a
vacuum unit coupled to said housing for creating a vacuum
therein.
14. The tissue cutting apparatus of claim 13 further including a
vacuum control circuit disposed between said control circuit and
said vacuum unit, said vacuum control circuit responsive to at
least one vacuum control signal provided by said control circuit to
control said vacuum unit.
15. The tissue cutting apparatus of claim 1, wherein: said motor
includes motor terminals for receiving signals from said control
circuit; and said control circuit includes a relay spanning said
motor terminals and operable in response to said motor stop signal
to cause a short circuit across said terminals.
16. A tissue cutting apparatus comprising: an elongated housing
configured for insertion into a body site, said housing having a
first end defining an opening adjacent thereto; a tissue cutting
tool disposed within said housing and defining at least one cutting
surface configured for movement relative to said housing adjacent
said opening to thereby excise tissue extending into said opening;
a motor driving a drive shaft extending therefrom and coupled to
said cutting tool, said motor operable to drive said cutting tool
at a cutting speed to excise tissue at said opening; means for
sensing a predefined position of said drive shaft relative to said
housing and producing a stop position signal corresponding thereto,
said predefined position corresponding to a position of said at
least one cutting surface relative to said opening to avoid
trapping unexcised tissue therebetween; means for generating a
motor stop signal when it is desired to stop the cutting apparatus;
and a control circuit responsive to said motor stop signal to drive
said motor at a predefined motor speed substantially less than said
cutting speed and thereafter responsive to said stop position
signal to deactivate said motor with said drive shaft at said
predefined position
17. The tissue cutting apparatus of claim 16, wherein said motor is
a brushed DC motor.
18. A method for controlling a brushed DC motor in a tissue cutting
apparatus having a cutting member, comprising the steps of:
operating the brushed DC motor at a cutting speed effective to
excise tissue with the tissue cutting apparatus; sensing a stop
signal indicative of a command to stop the tissue cutting
apparatus; thereafter sensing a first passage of the cutting member
by a fixed location relative to the cutting member; and thereafter
de-energizing the brushed DC motor when the cutting member is at
the fixed location so that movement of the motor stops with the
cutting member substantially at a predetermined position relative
to the fixed location.
19. The method according to claim 18, wherein: the step of
operating the brushed DC motor includes controlling the speed of
the motor using a current feedback loop; and further comprising the
step of disconnecting the current feedback loop after sensing the
stop signal.
20. The method according to claim 18 further comprising: after
sensing the first passage of the cutting member, reducing the speed
of the motor to a reduced speed effective to overcome the
rotational resistance of the brushed DC motor but substantially
less than said cutting speed.
21. The method according to claim 20, wherein the step of
de-energizing the motor occurs after sensing a second passage of
the cutting member by the fixed location.
22. The method according to claim 18, wherein the steps of sensing
the passage of the cutting member includes: providing a marker at a
predetermined position on the cutting member; and providing a
sensor at the fixed location on the cutting apparatus, the sensor
operable to generate a signal when the marker passes by the
sensor.
23. A method for controlling a brushed DC motor in a tissue cutting
apparatus having a cutting member, comprising the steps of:
operating the brushed DC motor at a cutting speed effective to
excise tissue with the tissue cutting apparatus; sensing a stop
signal indicative of a command to stop the tissue cutting
apparatus; sensing a first passage of the cutting member by a fixed
location relative to the cutting member; sensing a second passage
of the cutting member by the fixed location; and stopping the
brushed DC motor substantially immediately upon sensing the second
passage to stop the cutting member at a predetermined position.
24. A tissue cutting apparatus comprising: an elongated housing
configured for insertion into a body site, said housing defining a
cutting opening sized to receive tissue therethrough; a cutting
member operatively disposed within said housing and defining a
cutting surface adjacent said cutting opening configured to excise
tissue projecting through said opening; a brushed DC motor having a
rotating output shaft coupled to said cutting member and operable
to drive said cutting member at a cutting speed sufficient to
excise tissue, said brushed DC motor generating a resistance torque
in a direction opposite to the direction of rotation of said output
shaft; a position identifier mark associated with either of said
output shaft or said cutting member; a position sensor mounted in
said housing in alignment with said position identifier mark, said
sensor having a predetermined position relative to said cutting
opening so that when said position identifier mark is immediately
adjacent said position sensor, said cutting surface is disposed
relative to said opening so that tissue projecting through said
cutting opening is not trapped by said cutting surface; and means
for generating a stop signal when it is desired to stop operation
of said cutting member; and a motor controller providing power to
said brushed DC motor and having means for controlling the
operation of said motor, said means operable in a first state to
control said motor at said cutting speed, in a second state to
control said motor at a reduced speed sufficient only to overcome
said resistive torque in response to said stop signal, and a third
state to terminate power to said motor immediately after the second
passage of said position identifier mark by said position
sensor.
25. The tissue cutting apparatus according to claim 24, wherein
said motor controller includes: a power amplifier providing a
current signal to said motor; a current sensor sensing the current
provided to said motor and providing a current feedback to said
power amplifier, whereby said power amplifier is responsive to said
current feedback to control the current signal provided to said
motor; and a switch disposed between said current sensor and said
power amplifier operable to disable said current feedback to said
power amplifier in response to said stop signal.
26. The tissue cutting apparatus of claim 25, wherein: said motor
includes motor terminals for receiving signals from said control
circuit; and said motor controller includes a relay spanning said
motor terminals and operable in response to said stop signal to
cause a short circuit across said terminals.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to systems for
controlling motor driven surgical cutting instruments, and more
specifically to such systems for controlling the position of the
surgical cutting instrument upon stoppage of the drive motor. More
particularly, the invention relates to controlling a brush type DC
motor used to drive the cutting instrument.
BACKGROUND OF THE INVENTION
[0002] Minimally invasive surgical cutting instruments are known
and widely used to excise and remove biological tissue. Such
instruments typically include a handpiece comprising a cutting tool
housed within an elongated cannula, wherein the tool is disposed
adjacent to an opening at or near the tip of the cannula. The
cannula itself is configured for percutaneous insertion into a body
via a small incision, and is manually maneuvered into position for
tissue excision and removal.
[0003] Various configurations of cutting tools are known and may be
driven manually, pneumatically or via an electrically controlled
drive motor. In any case, tissue adjacent to the opening near the
tip of the cannula is typically excised by driving the cutting tool
with either a rotary or reciprocal motion relative to the cannula,
whereby tissue is drawn into the opening (typically via vacuum) and
excised by the cutting tool.
[0004] While motor driven surgical cutting instruments of the type
just described have been widely used in surgical applications, many
presently available designs suffer from a variety of drawbacks. For
example, if the position of the cutting tool is not controlled when
the drive motor is disabled, there exists a possibility that the
cutting tool may come to rest in a position that traps or pinches
unexcised tissue between a cutting surface of the cutting tool and
the opening near the tip of the cannula. To avoid this problem,
surgeons must typically maintain activation of the drive motor as
the tip of the instrument is moved or removed from the surgical
site, thereby compromising the accuracy and precision of the
procedure. The foregoing drawback becomes more problematic as the
complexity of the procedure increases, and is of particular concern
when performing delicate procedures such as removing vitreous
tissue during ocular surgery.
[0005] Designers of such surgical cutting instruments have
attempted to address the foregoing problem by providing various
systems for controlling motor position when stopping or disabling
the drive motor. An example of one such system for controlling the
position of a three-phase brushless DC motor is given in U.S. Pat.
No. 5,602,449 to Krause, et al. The Krause et al. disclosure
discloses an elaborate control system including multiple sensors
for determining motor armature position at 6.degree. intervals. As
is known in the art, brushless DC motors are typically speed driven
rather than torque driven and accordingly have little rotational
resistance associated with the operation thereof. Controlled
stoppage of such a motor is thus extremely difficult, if not
impossible, when the motor is operating at a high rotational speed,
and the Krause et al. system is accordingly responsive to a motor
stop signal to first decrease motor speed below some threshold
speed level and then perform a controlled stop based on armature
position.
[0006] Brushed DC motors, as compared with brushless DC motors, are
typically torque driven rather than speed driven, and accordingly
have a substantial rotational resistance associated therewith.
Thus, while the Krause et al. system may effectively provide for
controlled stopping of a surgical cutting instrument driven by a
brushless DC motor, such elaborate control techniques are
unnecessary when driving a brushed DC motor. What is therefore
needed is a simple and inexpensive control technique for
controlling the stop position of a brushed DC motor driven surgical
instrument. Ideally the control system should be operable to
control the position of the cutting tool when the drive motor is
turned off so that unexcised tissue is not trapped between the
cutting tool and the opening near the tip of the cannula.
SUMMARY OF THE INVENTION
[0007] The foregoing shortcomings of the prior art are addressed by
the present invention. In accordance with one aspect of the present
invention, a tissue cutting apparatus comprises an elongated
housing configured for insertion into a body site, the housing
having a first end defining an opening adjacent thereto. A tissue
cutting tool is disposed within the housing and defines at least
one cutting surface configured for movement relative to the housing
adjacent the opening to thereby excise tissue extending into the
opening.
[0008] In one feature of the invention, a brushed DC motor drives a
drive shaft coupled to the cutting tool. While the brushed motor is
rotary, the cutting tool can be driven in a rotary or reciprocating
fashion with an appropriate transmission mechanism between the
drive shaft and cutting tool. Means are provided for sensing a
predefined position of the drive shaft relative to the housing and
producing a stop position signal corresponding thereto. In one
embodiment, the sensing means is a Hall effect sensor and magnet
arranged between the motor and the cutting tool.
[0009] A motor control circuit is provided to control operation of
the motor. In one embodiment, the circuit includes a
pulse-width-modulated controller. In another embodiment, the motor
control circuit utilizes a current feedback to control the motor
current. With either embodiment, the motor control circuit is
operable in response to a motor stop signal to stop the motor with
the drive shaft at the predefined position. Certain features of the
motor control circuit are configured to take advantage of the
natural braking characteristics of the motor and cutting tool in
order to stop the motor at the appropriate position. This
predefined position is arranged to orient the cutting surface of
the cutting tool relative to the opening to avoid trapping
unexcised tissue between the cutting surface and a boundary of the
opening.
[0010] In one embodiment of the invention, the motor control
circuit includes an op amp driven current feedback loop to control
the current provided to the brushed motor. A switch is interposed
in the feedback loop to disable the current feedback signal when it
is desired to stop the motor. Eliminating the current feedback
improves the braking characteristics of the motor and handpiece so
that the cutting blade can be accurately stopped in its
predetermined position. With this embodiment, the control circuit
can respond to a motor stop signal to activate the feedback loop
switch. The motor is powered until the stop position signal is
received indicating that the drive shaft is at the predetermined
position, at which point current to the motor is ceased to stop the
cutter.
[0011] In another embodiment, the control circuit is responsive to
a motor stop signal to drive the motor at a predefined motor speed
less than the cutter operating speed. The control circuit is also
responsive to a second occurrence of the stop position signal to
deactivate the motor with the drive shaft at the predefined
position.
[0012] One object of the present invention is to provide an
improved surgical cutting apparatus that is operable to avoid
trapping unexcised tissue between the cutting tool and a boundary
of the opening in the cannula when the cutting tool drive motor is
deactivated.
[0013] Another object of the present invention is to provide such
improvements to surgical cutting apparatuses that have either a
rotating cutting tool or a linearly reciprocating cutting tool.
[0014] These and other objects of the present invention will become
more apparent from the following description of the preferred
embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a diagrammatic illustration of one embodiment of a
system for controlling the brushed DC motor of a motor driven
surgical instrument, in accordance with the present invention.
[0016] FIG. 2 is a diagrammatic illustration of the system of FIG.
1 showing further details of one embodiment of a motor control unit
and the surgical instrument.
[0017] FIG. 3A is a cross sectional illustration of the handpiece
of FIG. 2 showing details of a surgical instrument stop position
identification mechanism for a rotationally driven motor shaft.
[0018] FIG. 3B is a cross sectional illustration of the handpiece
of FIG. 2 showing details of a surgical instrument stop position
identification mechanism for a linearly driven motor shaft.
[0019] FIG. 4A is a cross sectional illustration of one embodiment
of a rotary surgical cutting tool disposed within the cannula of
the surgical instrument shown in FIG. 2.
[0020] FIG. 4B is a cross sectional illustration of the surgical
cutting tool of FIG. 4A, viewed along section lines 4B-4B, showing
the cutting surfaces of the cutting tool positioned remote from the
cannula opening.
[0021] FIG. 4C is a cross sectional illustration of the surgical
cutting tool of FIG. 4A, viewed along section lines 4C-4C, showing
one of the cutting surfaces of the cutting tool excising a portion
of the tissue forced into the opening near the cannula tip.
[0022] FIG. 4D is a cross sectional illustration of the surgical
cutting tool of FIG. 4A, viewed along section lines 4D-4D, showing
one of the cutting surfaces of the cutting tool trapping a portion
of the tissue between the cutting tool and the opening near the tip
of the cannula, which condition is avoided in accordance with the
present invention.
[0023] FIG. 5A is a cross sectional illustration of another
embodiment of a rotary surgical cutting tool disposed within the
cannula of the surgical instrument shown in FIG. 2.
[0024] FIG. 5B is a cross sectional illustration of the surgical
cutting tool of FIG. 5A, viewed along section lines 5B-5B, showing
the cutting surface of the cutting tool positioned adjacent to the
cannula opening.
[0025] FIG. 5C is a cross sectional illustration of the surgical
cutting tool of FIG. 5A, viewed along section lines 5C-5C, showing
the cutting surface of the cutting tool disposed remote from the
opening near the cannula tip after excising a portion of the tissue
extending into the cannula opening.
[0026] FIG. 5D is a cross sectional illustration of the surgical
cutting tool of FIG. 5A, viewed along section lines 5D-5D, showing
the cutting surface of the cutting tool trapping a portion of the
tissue between the cutting tool and the opening near the tip of the
cannula, which condition is avoided in accordance with the present
invention.
[0027] FIG. 6A is a cross sectional illustration of one embodiment
of a linearly reciprocating surgical cutting tool disposed within
the cannula of the surgical instrument shown in FIG. 2 showing the
cutting surface of the cutting tool positioned adjacent to the
cannula opening.
[0028] FIG. 6B is a cross sectional illustration of the surgical
cutting tool of FIG. 6A showing the cutting surface of the cutting
tool disposed remote from the opening near the cannula tip after
excising a portion of the tissue extending into the cannula
opening.
[0029] FIG. 6C is a cross sectional illustration of the surgical
cutting tool of FIG. 6A showing the cutting surface of the cutting
tool trapping a portion of the tissue between the cutting tool and
the opening near the tip of the cannula, which condition is avoided
in accordance with the present invention.
[0030] FIG. 7 is a cross sectional illustration of a further
embodiment of a linearly reciprocating surgical cutting tool
showing the cutting surface of the cutting tool trapping a portion
of the tissue between the cutting tool and the opening near the tip
of the cannula.
[0031] FIG. 8 is an electrical schematic of a motor control circuit
for use with one embodiment of the invention.
DESCRIPTION OF THE PREFERRED MBODIMENTS
[0032] For the purposes of promoting an understanding of the
principles of the invention, reference will now be made to the
embodiments illustrated in the drawings and specific language will
be used to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended, such alterations and further modifications in the
illustrated devices, and such further applications of the
principles of the invention as illustrated therein being
contemplated as would normally occur to one skilled in the art to
which the invention relates.
[0033] Referring to FIG. 1, one preferred embodiment of a system 10
for controlling a motor driven surgical cutting instrument, in
accordance with the present invention, is shown. System 10 includes
a main control unit (MCU) 12, which is preferably a
microprocessor-based system. MCU 12, as it relates to the present
invention, is operable to control the various operations of the
surgical cutting instrument 26 as well as manage the overall
operation of system 10. A foot switch 14, which may be of known
construction, is electrically connected to a number of inputs of
MCU 12 via an equal number, K, of signal paths 16, wherein K may be
any integer. As is known in the art, foot switch 14 is operated by
the surgeon to provide MCU 12 with control signals to signal
activation and deactivation of the cutting instrument 26 as well as
to control the cutting speed thereof.
[0034] A control panel 18, which may be of known construction, is
electrically connected to a number of inputs of MCU 12 via an equal
number, J, of signal paths 20, wherein J may be any integer.
Control panel 18 may include a number of control mechanisms for
controlling various features the cutting instrument or handpiece
26. Examples of such features may include, but are not limited to,
the flow of irrigation fluid (not shown) provided to the handpiece
26, control of a vacuum source 42 connected to the handpiece 26,
and the like.
[0035] A display unit 22, which may be of known construction, is
electrically connected to a number of outputs of MCU 12 via an
equal number, Q, of signal paths 24, wherein Q may be any integer.
Display unit 22 preferably includes provisions for displaying
various operational parameters of system 10 including, but not
limited to, operational status of the cutting instrument 26, the
speed of operation of the cutting tool 36, vacuum level, and the
like.
[0036] A surgical cutting instrument 36 is disposed within a
handpiece 26 and includes a brushed DC electrical motor 34 coupled
to the cutting instrument or tool 36 via a motor drive shaft as
will be described more fully hereinafter. The motor 34 is
electrically connected to a motor control unit 28 via a number, M,
of signal paths 30 wherein M may be any integer. The motor control
unit 28 is, in turn, connected to a number of outputs of MCU 12 via
an equal number, N, of signal paths 32. A motor shaft position
sensor 38 is electrically connected to a motor shaft position
feedback input (SPF) of MCU 12 via signal path 40, and provides a
motor stop identification signal thereon as will be more fully
described hereinafter. As it relates to the present invention, the
motor shaft stop identification signal provided by sensor 38 on
signal path 40 preferably provides MCU 12 with a motor stop
identification signal as well as a cutter speed signal that is
proportional to the motor speed for a geared system or identical to
the motor speed for a direct drive system.
[0037] Handpiece 26 is further mechanically connected to a vacuum
unit 42 via conduit 44, whereby the vacuum unit 42 provides a
controllable vacuum level to handpiece 26 for suctioning excised
tissue as is known in the art. Vacuum unit 42 is electrically
connected to a vacuum control unit 46 via a number, P, of signal
paths wherein P may be any integer. The vacuum control unit 46 is,
in turn, connected to a number of outputs of MCU 12 via an equal
number, L, of signal paths 50, wherein L may be any integer. A
vacuum sensor 52, which may be a temperature compensated
solid-state pressure sensor, is preferably positioned within the
conduit 44 and is electrically connected to a vacuum feedback (VF)
input of MCU 12 via signal path 54. Alternatively, the vacuum
sensor 52 may be disposed within handpiece 26 or within the vacuum
unit 42 itself.
[0038] In operation, the MCU 12 is responsive to a vacuum command
signal, preferably provided by a corresponding control mechanism
associated with control panel 18 or equivalent control mechanism,
to provide one or more corresponding vacuum control signals to
vacuum control unit 46 along signal paths 50. The vacuum control
unit 46, in turn, is responsive to the one or more vacuum control
signals to activate the vacuum unit 42 to thereby provide handpiece
26 with a desired level of vacuum. The actual vacuum level provided
to handpiece 26 is sensed by vacuum sensor 52 which provides a
corresponding vacuum feedback signal to the vacuum feedback input
VF of MCU 12. The MCU 12 is then operable to compare the vacuum
feedback signal with the vacuum command signal and correspondingly
adjust the one or more vacuum control signals to achieve the
desired vacuum level within handpiece 26. Such closed-loop feedback
techniques are well known in the control systems art.
[0039] In one alternative embodiment, the MCU 12 can be replaced by
individual microprocessors controlling the input and output for
controlling the operation of the motor driver 58 and the vacuum
generator unit 42. In this alternative embodiment, the motor
control and vacuum control microprocessors can be PIC16Cxx Series
microcontrollers provided by Microchip, Inc. of Chandler Ariz. The
motor control microcontrollers can receive input signals from the
motor driver 58 and position sensor 38, as well as the foot switch
14 and panel controls 18. Likewise, the vacuum microcontroller can
receive input signals from the vacuum sensor 52, the foot switch
and panel controls. Each microcontroller can provide its own output
to its driven component and have its own display, such as an LED
display, indicative of its operational status. Moreover, the two
units can communicate with each other to ensure clean cutting by
proper timing of the cutting and aspiration functions.
[0040] In one preferred embodiment, the handpiece, or tissue
cutting instrument, 26 includes a control portion 62 having an
elongated housing or cannula 64 extending therefrom. The cannula 64
terminates at a cannula tip 66 and defines an opening 68 near the
tip 66. The cannula 64 is generally hollow and houses any of the
various embodiments of the tissue cutting tool 36 as illustrated in
FIGS. 4A, 5A, 6A and 7. In any case, cannula 64 is configured for
insertion into a body site, and in one specific application of
system 10 cannula 64 is configured to perform percutaneous ocular
surgery. The connection of the vacuum unit 42 to cutting instrument
26 via conduit 44 is omitted in FIG. 2 for brevity and clarity of
illustration of the brushed DC drive motor 34 and related
components. It is to be understood, however, that such a vacuum
connection is made to instrument 26 and is typically made between
cannula 64 and control section 62. Moreover, although not
specifically shown in the drawings, an irrigation fluid connection
may also be made to cutting instrument 26 so that irrigation fluid
may be passed to the surgical site via cannula opening 68.
[0041] Referring now to FIGS. 2 and 3A, preferred embodiments of
the motor control unit 28 and handpiece 26 are shown in greater
detail. The motor control unit 28 in one embodiment includes a
pulse width modulation (PWM) generator circuit 56 having a motor
speed input connected to one of the MCU outputs 32.sub.1. The
output 32.sub.1 can provide a variable voltage signal indicative of
a desired motor speed and based upon the position of a throttle or
foot pedal. In certain embodiments, an additional input is
connected to another one of the MCU outputs 32.sub.2. The signal at
this output 32.sub.2 can be a motor slowdown signal as described
below. Alternatively, the output 32.sub.2 can constitute a braking
signal used in connection with a current feedback motor controller,
as depicted in FIG. 8. As a further alternative, the slowdown
command may be communicated via the motor speed command itself,
rather than through a separate signal 32.sub.2. In this instance,
the output 32.sub.2 may not be required.
[0042] In the illustrated embodiment, the PWM is disposed within
the motor control unit. Alternatively, the PWM can be integrated
into the MCU 12, or into the separate motor control microprocessor
discussed above. The motor speed input receives a motor speed
signal from MCU 12 indicative of desired operational speed of the
drive motor 34. The slowdown input can receive a speed adjustment
signal from the MCU 12 based on the actual motor speed signal
provided by a motor sensor 76 associated with the drive motor 34,
which motor sensor 76 will be described in greater detail
hereinafter.
[0043] A motor driver circuit 58 is electrically connected to PWM
generator circuit 56 via signal path 60 and receives a PWM drive
signal therefrom, which is a pulse width modulated signal
indicative of desired drive motor speed. The motor driver circuit
58 provides a motor drive signal (MD) to drive motor 34 via signal
path 30. While the preferred embodiment contemplates digital
control of the motor using the PWM generator circuit 56,
alternative embodiments can utilize closed loop feedback analog
circuits, particularly where slower cutting speeds are
contemplated. One alternative controller is illustrated in FIG. 8
and described in more detail herein.
[0044] The motor drive signal includes a motor stop input that is
connected to another one of the MCU outputs 32.sub.3. In accordance
with the present invention, MCU provides a motor stop signal on
signal path 32.sub.3, based on a motor deactivation command
provided by foot switch 14 and also based on a motor stop
identification signal provided by sensor 38, to stop the tissue
cutting tool 36 in a desired position, as will be more fully
described hereinafter. In certain embodiments, only the motor stop
signal is utilized to command the motor to stop at the
predetermined position. In these certain embodiments, the motor
slowdown signal on path 32.sub.2 can be eliminated, or the input on
path 32.sub.2 can be used for other control signals to the motor
control circuit.
[0045] Drive motor 34 is preferably a known brushed DC electrical
motor operable to drive a rotary motor shaft 70 connected thereto.
In one embodiment of the present invention, the rotary motor shaft
70 is connected directly to a drive shaft 74 of a rotary cutting
tool (see FIGS. 4A-4D and 5A-5D) disposed within the cannula 64 so
that the cutting tool rotates about a longitudinal axis defined by
the elongated cannula 64. In an alternative embodiment, the rotary
motor shaft 70 is connected to one end of a transmission mechanism
72 which is operable to convert the rotary motion of the shaft 70
to a linearly reciprocating motion. The opposite end of the
transmission mechanism 72 is connected to the drive shaft 74 of a
linearly reciprocating cutting tool (see FIGS. 6A-6C, or 7)
disposed within the cannula 64 so that the cutting tool
reciprocates along the longitudinal axis of the cannula 64. An
example of one known transmission mechanism for converting the
rotary motion of shaft 70 to a linearly reciprocating motion is
described in U.S. Pat. No. 5, 411,513 to Ireland et al., the
disclosure of which is incorporated herein by reference.
[0046] Referring now to FIGS. 3A and 3B, preferred embodiments of a
mechanism for determining the motor stop identification signal are
shown. In the case that motor drive shaft 70 is connected directly
to the drive shaft 74 of a rotary cutting instrument (FIGS. 4A and
5A), as shown in FIG. 3A, sensor 38 is preferably disposed within,
or attached to, an inner surface of handpiece 26. A channel 25 is
preferably formed within handpiece 26 and signal path 40 is
disposed within channel 25 and electrically connected to sensor 38.
In this manner, signal path 40 is isolated from the interior of
handpiece 26. Shaft 70, shown in FIG. 3A as rotatably driven in the
direction indicated by arrow 75, includes a shaft position
identification mark 76 attached thereto or formed integral
therewith. In the case that motor drive shaft 70 is connected to a
transmission unit 72 which is then connected to the drive shaft 74
of a linearly reciprocating cutting instrument (see FIGS. 6A and
7), as shown in FIG. 3B, shaft 74 is linearly driven in the
direction indicated by arrow 79 and includes a shaft position
identification mark 77 attached thereto or formed integral
therewith. Alternatively, mark 76 positioned on shaft 70 may be
used even though handpiece 26 includes a transmission unit 72. In
any case, sensor 38 is preferably a known Hall effect sensor,
although the present invention contemplates utilizing other known
sensors such as a variable reluctance sensor and the like. Marks 76
and 77 are preferably magnetized identifiers that align with sensor
38 when the cutting instrument is in a preferred stop position.
Sensor 38 is operable to sense passage thereby of mark 76 or 77 and
provide corresponding shaft speed and motor stop identification
signals to input shaft position feedback input SPF of MCU 12 via
signal path 40.
[0047] Referring now to FIGS. 4A-4D, one embodiment 80 of the
tissue cutting tool 36 of FIG. 1 in relation to the cannula 64 is
shown. The rotary tissue cutting tool 80, as shown in FIG. 4A,
preferably includes a shaft 82 connected to, or integral with, the
rotary drive shaft 70 of FIG. 2. Since cutting tool 80 is
configured for rotary motion within cannula 64, the transmission
mechanism 72 is omitted and drive shafts 70 and 74 comprise a
single drive shaft. Adjacent to the opening 68 formed near the tip
66 of cannula 64, the cutting tool 80 defines a number of blades or
fins 84 that act as cutting surfaces. A vacuum is established
within the cannula 64 via vacuum unit 42 (FIG. 1) so that a suction
force is developed at the cannula opening 68 in the direction
indicated by arrow 85.
[0048] Referring to FIG. 4B, the drive motor 34 is activated
pursuant to a motor activation command, typically provided via foot
switch 14, wherein MCU 12 and motor control unit 28 are operable to
process such a command as described hereinabove to cause motor 34
to rotate the one or more blades 84 in the direction indicated by
arrow 86. The suction developed at the opening 68 of the cannula
draws nearby tissue T into the opening 68 when the one or more
blades 84 are disposed remote from the opening 68. As the one or
more blades 84 rotate adjacent to the cannula opening 68, a portion
of the tissue ET extending into opening 68 is excised as shown in
FIG. 4C. The excised tissue ET is drawn away from opening 68 via
vacuum and is collected by a suitable tissue container (not
shown).
[0049] The brushed DC drive motor 34 is deactivated, and the one or
more blades 84 correspondingly cease to rotate, pursuant to a motor
stop command provided by foot switch 14. However, unless the
position of the rotary shaft 70, and hence the position of the one
or more blades 84 relative to the cannula opening 68, is
appropriately controlled when the motor 34 is deactivated, one of
the blades 84 may come to rest partially disposed over opening 68
and consequently trap a portion of the tissue T' between the blade
84 and a boundary of the opening 68 as illustrated in FIG. 4D.
Efforts at withdrawing the cannula 64 from the surgical site may
accordingly result in tearing of the tissue portion T' away from
the tissue base T. Heretofore, the surgeon encountering such tissue
trapping would typically be required to re-activate the cutting
tool 80 to release the tissue portion T' from its base T. In
accordance with the present invention, however, such tissue
trapping is avoided.
[0050] Referring now to FIGS. 5A-5D, another embodiment 90 of the
tissue cutting tool 36 of FIG. 1 in relation to the cannula 64 is
shown. The rotary tissue cutting tool 90, as shown in FIG. 5A,
preferably includes an elongated hollow tube 92 connected to, or
integral with, the rotary drive shaft 70 of FIG. 2. Since cutting
tool 90 is configured for rotary motion within cannula 64, the
transmission mechanism 72 is omitted and drive shafts 70 and 74
comprise a single drive shaft. Adjacent to the opening 68 formed
near the tip 66 of cannula 64, the cutting tool 90 defines an
opening 94 defining a cutting surface at its boundary. Vacuum is
established within the cannula 64 via vacuum unit 42 (FIG. 1) so
that a suction force is developed at the cannula opening 68 in the
direction indicated by arrow 95.
[0051] Referring to FIG. 5B, the drive motor 34 is activated as
described above to cause motor 34 to rotate the cutting opening 94
defined within cutting tool 90 in the direction indicated by arrow
96. The suction developed at the opening 68 of the cannula draws
nearby tissue T into the opening 68 when the cutting tool opening
94 is aligned with the cannula opening 68. As the cutting tool
opening 94 rotates away from the cannula opening 68, a portion of
the tissue ET extending into openings 68 and 94 is excised as shown
in FIG. 5C. The excised tissue ET is drawn away from opening 68 via
vacuum and is collected by a suitable tissue container (not
shown).
[0052] As with the embodiment illustrated in FIGS. 4A-4D, the
cutting tool opening 94 may come to rest partially disposed over
opening 68 and consequently trap a portion of the tissue T' between
a boundary of the cutting tool opening 94 and a boundary of the
cannula opening 68, as illustrated in FIG. 5D, unless the position
of the rotary shaft 70, and hence the position of the cutting tool
opening 94 relative to the cannula opening 68, is appropriately
controlled when the motor 34 is deactivated. Again, efforts at
withdrawing the cannula 64 from the surgical site may accordingly
result in tearing of the tissue portion T' away from the tissue
base T, and a surgeon encountering such tissue trapping would
typically be required to re-activate the cutting tool 90 to release
the tissue portion T' from its base T.
[0053] Referring now to FIGS. 6A-6C, yet another embodiment 100 of
the tissue cutting tool 36 of FIG. 1 in relation to the cannula 64
is shown. The linearly reciprocating tissue cutting tool 100
preferably includes an elongated hollow tube 102 connected to, or
integral with, the drive shaft 74 of FIG. 2. Since cutting tool 100
is configured for linearly reciprocating motion within cannula 64,
the transmission mechanism 72 is operatively connected between
drive shafts 70 and 74. Adjacent to the opening 68 formed near the
tip 66 of cann1aula 64, the cutting tool 100 defines an opening 104
defining a cutting surface at its boundary. Vacuum is established
within the cannula 64 via vacuum unit 42 (FIG. 1) so that a suction
force is developed at the cannula opening 68 in the direction
indicated by arrow 105.
[0054] The drive motor 34 operates as described to reciprocate the
cutting opening 104 defined within cutting tool 100 linearly along
the longitudinal axis of cannula 64. The suction developed at the
opening 68 of the cannula draws nearby tissue T into the opening 68
when the cutting tool opening 104 is aligned with the cannula
opening 68. As the cutting tool opening 94 pulls away from the
cannula opening 68, a portion of the tissue ET extending into
openings 68 and 104 is excised as shown in FIG. 5B. The excised
tissue ET is drawn away from opening 68 via vacuum and is collected
by a suitable tissue container (not shown).
[0055] As with the embodiments illustrated in FIGS. 4A-4D and
5A-5D, the cutting tool opening 104 may come to rest partially
disposed over opening 68 and consequently trap a portion of the
tissue T' between a boundary of the cutting tool opening 104 and a
boundary of the cannula opening 68, as illustrated in FIG. 6C,
unless the position of the rotary shaft 70, and hence the position
of the cutting tool opening 104 relative to the cannula opening 68,
is appropriately controlled when the motor 34 is deactivated.
Again, efforts at withdrawing the cannula 64 from the surgical site
may accordingly result in tearing of the tissue portion T' away
from the tissue base T, and a surgeon encountering such tissue
trapping would typically be required to re-activate the cutting
tool 100 to release the tissue portion T' from its base T.
[0056] The reciprocating cutting instrument shown in FIGS. 6A-C can
be modified to an end cutting configuration, such as depicted in
FIG. 7. In this configuration, the cutting tool 106 is open at its
distal end. The distal end 108 defines a circumferential cutting
surface that excises the tissue T. As shown in FIG. 7, the cutting
tool 106 can be stopped in a position in which a portion of the
tissue is trapped between the cutting opening in the outer cannula
and the cutting surface 108, leading to the phenomena described
above. The motor control system according to the illustrated
embodiments of the present invention can adjust the stopped
position of the cutting tool 106 so the end cutting surface 108 is
clear of the cannula cutting opening.
[0057] In accordance with the present invention, the tissue
trapping conditions illustrated in FIGS. 4D, 5D, 6C and 7 are
avoided by controlling deactivation of the drive motor 34 in such a
manner that the cutting surface(s) of the various cutting tools are
positioned remote from the cannula opening 68. Referring again to
FIGS. 2, 3A and 3B, controlled deactivation of the drive motor 34
will now be described in detail.
[0058] When it is desired to deactivate a presently activated
cutting tool, such as any of the cutting tools illustrated in FIGS.
4A-4D, 5A-5D, 6A-6C or 7, a motor stop command is provided via foot
switch 14 (FIG. 1). In one embodiment, MCU 12 is responsive to the
motor stop command to provide a slowdown signal to the PWM
generator via signal path 322 which slows the action of motor 34.
Preferably, the slowdown signal corresponds to a predefined signal
level operable to drive the motor 34 at a motor speed below a motor
speed threshold level. Since motor 34 is a brushed DC motor, it has
a rotational resistance or resistive torque associated therewith as
described above. In addition, in some cases friction between the
inner and outer needles will increase the rotational resistance.
Due to this combined rotational resistance, operation of the motor
34 will cease very rapidly or nearly instantly if the motor drive
signal on signal path 30 is disabled while driving motor 34 below
the motor speed threshold. Accordingly, alignment of mark 76 or 77
with sensor 38 preferably corresponds to a position of the cutting
instrument at which there is no danger of trapping tissue between a
cutting surface thereof and the cannula opening, and sensor 38 is
operable to produce the motor stop identification signal when so
aligned with mark 76 or 77. Alternatively, although mark 76 or 77
is preferably at the open position, it may be located at any known
displacement from the open position, so long as sufficient delay is
controllably introduced in the activation of the brake signal. This
delay can compensate for the displacement of the alignment mark 76
or 77.
[0059] In one embodiment, MCU 12 is preferably operable to produce
a motor stop signal on signal path 323 when sensor 38 detects
alignment of mark 76 or 77 therewith after one passage thereby of
mark 76 or 77 since producing the slowdown signal on signal path
322. Allowing one passage of mark 76 or 77 by sensor 38 after
issuing the slowdown signal ensures that the drive speed of motor
34 is at or below the motor speed threshold when subsequently
issuing the motor stop command, regardless of the position of mark
76 or 77 relative to sensor 38 when the slowdown command was
issued. After one passage of mark 76 or 77 by sensor 38 since
issuing the slowdown signal, MCU 12 is responsive to the signal
provided by sensor 38 indicative of alignment of mark 76 or 77
therewith, to produce the motor stop signal on signal path 323. The
motor driver 58 is responsive to the motor stop signal to produce a
motor disable signal on signal path 30. Due to the inherent
rotational resistance, motor 34 is responsive to the motor disable
signal to immediately cease operation thereof with mark 76 or 77
substantially aligned with sensor 38, and with the cutting
instrument accordingly positioned so as not to trap tissue between
any cutting surface thereof and the cannula opening. It is
contemplated that the stopped position of the motor, and therefore
the cutting surface, may be instead aligned with a predetermined
differential distance between the mark 76/77 and the sensor 38. The
braking characteristics of the cutter and its motor can be
ascertained and the stopping distance determined so that this
predetermined differential distance can be calibrated
accordingly.
[0060] For example, with cutting tool 80, MCU 12 is preferably
operable to stop the drive motor 34 as just described with the
cutting blades 84 positioned as illustrated in FIG. 4B, although
the present invention contemplates stopping the drive motor 34 with
cutting blades 84 positioned otherwise relative to cannula opening
68 so long as tissue pinching does not occur as illustrated in FIG.
4D. With cutting tool 90, MCU 12 is preferably operable to stop the
drive motor 34 as just described with the cutting opening 94
positioned as illustrated in FIG. 5C, although the present
invention contemplates stopping the drive motor 34 with cutting
opening 94 positioned otherwise relative to cannula opening 68 so
long as tissue pinching does not occur as illustrated in FIG. 5D.
Finally, with cutting tool 100, MCU 12 is preferably operable to
stop the drive motor 34 as just described with the cutting opening
104 positioned as illustrated in FIG. 6B, although the present
invention contemplates stopping the drive motor 34 with cutting
opening 104 positioned otherwise relative to cannula opening 68 so
long as tissue pinching does not occur as illustrated in FIG.
6C.
[0061] In some instances, the actual motor speed will be below the
motor speed threshold when the motor stop command is issued by the
surgeon. In these instances, the MCU can be programmed to recognize
this condition and bypass the requirement of one passage of the
mark 76 or 77 past the sensor. If the motor speed is already
sufficiently slow, the MCU can simply disable the motor when the
mark first encounters the sensor.
[0062] In a further modification, the motor disable signal can be
provided to a relay spanning the motor terminals, such as relay 110
shown in phantom within the handpiece depicted in FIG. 2.
Energizing the relay shorts across the terminals to immediately
"kill" the motor. This motor short approach adds to the rotational
resistance described above to ensure that the motor can be stopped
repeatably and reliably. In addition, the shorting relay serves as
a sort of fail-safe feature that prevents the possibility that
motor can become re-energized while the cutting instrument is being
removed from the patient. Alternatively, the motor slowdown signal
can be eliminated, but the motor speed signal set to a speed of
zero, which effectively results in shorting of the drive outputs.
This action is equivalent to activating the relay 110, with the
same improvements in stopping time.
[0063] In an alternative approach, the motor slowdown signal is
eliminated. In this instance, the rotational resistance or natural
braking characteristics of the motor and cutter can be quantified
to determine how far the motor will rotate once current is
terminated to the motor. Current can be supplied to the motor even
after a motor stop signal has been received, until the motor
control circuit receives a motor stop identification signal
generated by the sensor 38. With the approach, the sensor 38 can be
placed offset from the predetermined position at which cutting
surface is clear of the cannula cutting opening. Thus, when the
signal from sensor 38 is received, current to the motor can be
terminated and the motor will coast to a stop at the appropriate
position.
[0064] In the prior embodiment, the motor control circuit
implements pulse width modulation to control the motor speed and
operation. In a further embodiment, a control circuit shown in FIG.
8 relies upon current feedback to control the motor speed.
Specifically, the control circuit 110 includes a current sensor 112
and a power amplifier circuit 112. The motor drive signal 116 is
provided at the output of the power amplifier circuit 112. A speed
control signal 118 is supplied as an input to the amplifier 114
circuit based upon a throttle position. The speed control signal
118 can be supplied at the signal path 32 (FIG. 1). Current to the
motor drive signal 116 is delivered through the resistor 122. The
output of the power amplifier circuit 112 is fed directly and
through resistor 122 to a difference amplifier 124 in the current
sensor 114. The output 126 of the difference amplifier is provided
as a feedback signal to an input of the power amplifier circuit
112.
[0065] The amplifier circuit includes an op amp 128 that receives
the feedback output 126 and the signal input 118 conditioned
through a resistor 130. A resistor 134 scales and amplifies the
input signals to supply the current signal to the motor drive
signal 116.
[0066] In one aspect of the present embodiment, a feedback disable
switch 136 is interposed between the feedback output 126 and the
input to the power amplifier circuit 112. A braking signal 120 is
supplied to the switch 136 to determine its state. In the
illustrated position in FIG. 8, the switch 136 connects the
feedback output 126 to the power amplifier circuit input. In its
alternative position, the switch 136 connects the feedback output
126 to ground, thereby disabling the current feedback control
feature of the drive circuit 110. In this instance, the absence of
the current feedback increases the natural braking characteristics
of the handpiece and drive motor.
[0067] The braking signal input 120 can be derived from the motor
stop signal 32.sub.3 identified in FIG. 2. Alternatively, the
braking signal input 120 can be connected to the output 32.sub.2,
which had been used for a slowdown signal with the motor control
circuit shown in FIG. 2. As with the prior embodiments, the motor
control circuit 110 relies upon the natural rotational resistance
and braking characteristics of the motor and cutter. These
characteristics are particularly pronounced for a brushed DC motor
and can be readily quantified.
[0068] While the invention has been illustrated and described in
detail in the foregoing drawings and description, the same is to be
considered as illustrative and not restrictive in character, it
being understood that only the preferred embodiments have been
shown and described and that all changes and modifications that
come within the spirit of the invention are desired to be
protected.
* * * * *