SURGICAL TOOL SYSTEM WITH A POWRED HANDPIECE AND A CONSOLE, THE CONSOLE ABLE TO PROVIDE ENERGIZATION SIGNALS TO THE HANDPIECE IN EITHER A MOTOR DRIVE MODE OR A DIRECT DRIVE MODE

• US 20080114388A1
• Filed: 10/29/2007
• Published: 05/15/2008
• Est. Priority Date: 08/15/1996
• Status: Active Grant

• Current Assignee: David E. Monk, Jerry A. Culp, Kevin J. Schemansky
• Original Assignee: David E. Monk, Jerry A. Culp, Kevin J. Schemansky
• Inventors: Monk, David E., Culp, Jerry A., Schemansky, Kevin J.
• Granted Patent: US 7,998,157 B2
• Time in Patent Office: Days
• US Class Current: 606/170
• CPC Class Codes: A61B 17/1622 Drill handpieces A61B17/1626, A61B17/1628 take precedence
• CPC Class Codes: A61B 17/1626 Control means; Display units
• CPC Class Codes: A61B 17/32002 with continuously rotating, oscillating or reciprocating cutting instruments
• CPC Class Codes: A61B 18/14 Probes or electrodes therefor
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00137 Details of operation mode
• CPC Class Codes: A61B 2017/00199 with a console, e.g. a control panel with a display
• CPC Class Codes: A61B 2017/00367 Details of actuation of instruments, e.g. relations between pushing buttons, or the like, and activation of the tool, working tip, or the like
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/0046 with a releasable handle; with handle and operating part separable for prosthetic joint-implanting tools A61F2/4603
• CPC Class Codes: A61B 2017/00464 for use with different instruments with hole for different instruments A61B2017/22072
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00482 with a code
• CPC Class Codes: A61B 2017/00973 pedal-operated
• CPC Class Codes: A61B 2017/320069 for ablating tissue
• CPC Class Codes: A61B 2017/320071 with articulating means for working tip
• CPC Class Codes: A61B 2017/320084 Irrigation sleeves
• CPC Class Codes: A61B 2034/258 providing specific settings for specific users
• CPC Class Codes: A61B 90/90 Identification means for patients or instruments, e.g. tags
• CPC Class Codes: A61B 90/98 using electromagnetic means, e.g. transponders
• CPC Class Codes: A61M 2205/6018 : providing set-up signals for the apparatus configuration

Abstract

A surgical tool system including a handpiece with a power generating unit and a control console for supplying energization signals to the power generating unit. Based on the data in a memory associated with the handpiece, the control console supplies energization signals to the handpiece power generating unit in either a motor drive mode or a direct drive mode. In the motor drive mode the signals are supplied to windings integral with the power generating unit based on the position of a rotor also part of the power generating unit. In the direct drive mode, energizaiton signals are supplied to the power generating unit independent of rotor position.

Claims

1. A surgical tool system, said system including:

a surgical handpiece, said surgical handpiece including a power generating unit that is actuated in response to application of an enegization signal;

an accessory that extends from said handpiece for application to a surgical site, said accessory being connected to said power generating unit for actuation by said power generating unit;

a memory integral with said handpiece, said memory including data indicating how energization signals are to be applied to said handpiece power generating unit; and

a control console, said control console including;

a socket to which said handpiece is removably connected so that, at different times, different said surgical handpieces can be connected to said socket;

a driver for supplying power supply for supplying energization signals to said handpiece power consuming unit through said socket, wherein if the handpiece power consuming unit is a motor, said drive is able to apply energization signals to the windings of the motor to commutate the windings;

a controller connected to said socket for receiving therefore data read from said memory integral with the powered surgical handpiece and to said driver for regulating operation of said driver, said control configured so that;

if the data in said memory indicates said handpiece power generating unit is to be driven in a motor drive mode, said control console causes said driver to supply energization signals to the handpiece power generating unit to commutate windings integral with said power generating unit based on the signals from said handpiece representative of the position of a rotor integral with said power generating unit that are received by said control console;

or

if the data in said memory indicates said handpiece power generating unit is to be driven in a direct drive mode, said control console cause said driver to supply energization signals to the handpiece power consuming unit independent of the position of signals representative of rotor position.

2. The surgical tool system of claim 1, wherein said cutting accessory is removably attached to said handpiece and removably coupled to said power generating unit.

3. The surgical tool system of claim 1, wherein said handpiece power generating unit is one selected from the group consisting of:

a motor;

a tool that emits light energy;

a tool that emits ultrasonic energy; and

a tool that cauterizes tissue.

4. The surgical tool system of claim 1, wherein said memory is contained in said handpiece.

5. The surgical tool system of claim 1, wherein:

said handpiece generating unit is a brushless sensorless motor that emits back EMF signals to said control console; and

said control console uses the back EMF signals to determine motor rotor position.

6. The surgical tool system of claim 1, wherein:

said handpiece generating unit is a brushless sensorless motor that emits back EMF signals to said driver; and

said driver uses the back EMF signals to determine motor rotor position.

8. The control console of claim 6, wherein, when said driver is set to commutate the handpiece power generating unit windings based on signals representative of rotor position, said driver receives from the handpiece the signals representative of rotor position, and commutates the windings based on the received signals.

9. The control console of claim 6, wherein, when said driver is set to commutate the handpiece power generating unit windings based on signals representative of rotor position, said driver receives from the handpiece windings back EMF signals that are based on rotor position and commutates the windings based on the received back EMF signals.

7. A control console for use with a powered surgical handpiece, said control console including:

a socket to which a powered surgical handpiece is removably connected so that, at different times, different said surgical handpieces can be connected to said socket;

a driver for supplying power supply for supplying energization signals to a power consuming unit internal to the powered surgical handpiece through said socket, wherein if the handpiece power consuming unit includes windings and a rotor, said driver is able to apply energization signals to the windings to commutate the windings;

a controller connected to said socket for receiving therefrom data read from a memory integral with the powered surgical handpiece and to said driver for regulating operation of said driver, said control configured to, based on the data read from the handpiece memory;

cause said driver to supply energization signals to the handpiece power generating unit to commutate the windings based on the signals from said handpiece representative of the position of the rotor;

or

cause said driver to supply energization signals to the handpiece power consuming unit independent of the position of signals representative of rotor position.

10. A powered surgical handpiece, said handpiece including:

a body;

a power outputting device disposed in said body, that consumes electrical power;

a accessory that is connected to said power outputting device to apply the power output by said device to a surgical site; and

a memory integral with said body, said memory containing data indicating if a control console to which said handpiece is attached is to apply power to individual windings integral with said power generating device based on the position of a signals output by said power generating device representative of a rotor integral with the power generating device or independent of signals representative of device rotor position.

11. The powered surgical handpiece of claim 10, further including a coupling assembly attached to said body for releasably connecting said accessory to said power generating unit.

12. The powered surgical handpiece of claim 10, wherein said power generating unit includes windings and a rotor, is brushless and sensors and is configured to forward back EMF signals from said windings to the control console as rotor position signals.

13. A powered surgical tool system, said system including:

a powered handpiece with an accessory for application to a surgical site, said handpiece having a power consuming unit to which energization signals are applied for actuating said accessory, said power generating unit operating at given rate when energized, the rate being a quantifable parameter;

a control console configured to be connected to said handpiece for applying energization signals thereto and for determining the operating rate thereof, said control console including;

a display for presenting images regarding the operation of said handpiece; and

a controller connected to said handpiece for regulating the application of energization signals to said handpiece and to said display for regulating the images presented on said video display, said main controller configured so that;

when energization signals are not applied to said handpiece, said controller causes a user time image to be presented on said display, said user time image including a primary component that presents information about the operating rate of said handpiece and a secondary component that presents information different from the handpiece operating rate, wherein the primary component occupies a first area on said display; and

when energization signals are applied to said handpiece, said controller causes a run time image to be presented on said display, said run time image including a primary component that presents information about the operating rate of said handpiece and secondary component that presents information different from the handpiece operating rate, wherein the primary component of the run time image occupies a second area on said display, the second area being greater than the first area.

14. A method of operating a powered surgical system that includes:

a handpiece with a tool that includes a power generating unit and an accessory that is connected to the power generating unit for application to a surgical site; and

a display;

prior to applying an energizing signal to the handpiece power generating unit, presenting on the display a user time image that includes;

a primary component that presents information about the operating rate of said handpiece; and

a secondary component that presents information different from the handpiece operating rate, wherein there the user time image primary component occupies a first area on the display;

applying an energization signal to the handpiece power generating unit to actuate the power generating unit;

monitoring the operating rate of the handpiece power generating unit during said step of applying an energization signal to the handpiece power generating unit;

during said steps so applying an energization signal to the handpiece power generating unit and monitoring the operating rate of the power generating unit, presenting on the display a run time image that includes;

a primary component that presents information about the operating rate of said handpiece; and

secondary component that presents information different from the handpiece operating rate, wherein the run time image primary component occupies a second area on the display, the second area being greater than the first area.

15. A surgical tool system, said system including:

a handpiece, said handpiece having;

a variable speed motor that is actuated in response to the application of an energization signal; and

a cutting accessory for application to a surgical site that is connected to said motor for actuation by said motor;

a memory integral with said handpiece, said memory including data representative of the rate at which said handpiece motor should be accelerated; and

a control console, said control console including;

a socket to which said surgical handpiece can be connected to so that, at different times, different said surgical handpieces can be connected to said socket;

a motor control assembly for generating the energization signal for application to the handpiece motor wherein said motor control assembly, in response to a first motor control signal, selectively modulates the energization signal and the energization signal is applied to the handpiece motor through said socket; and

a processor connected to;

said handpiece for receiving an indication of the speed of the motor;

said memory;

to a user-actuated control member that outputs a setpoint signal representative of a user-selected speed for the handpiece motor; and

to said motor control assembly for applying the first motor control signal to said motor control assembly wherein, said processor is configured to;

read from said memory the data representative of the rate at which said handpiece motor should be accelerated;

compare the speed of the handpiece motor to the speed represented by the setpoint signal; and

if the comparison indicates that the speed of the handpiece motor is below the setpoint signal speed, apply the first motor control signal to said motor control assembly so that said motor control assembly generates the energization signal to the handpiece motor that causes the handpiece motor to accelerate towards the setpoint signal speed at a rate of acceleration based on the acceleration rate data read from said memory.

16. The surgical tool system of claim 15, wherein said processor is configured to apply the first motor control signal to said motor control assembly so that said motor control assembly generates energization signals to said handpiece motor that causes said handpiece motor to accelerate at a rate not greater than the acceleration rate in the data read from said memory;

17. The surgical tool system of claim 15, wherein:

said memory includes data representative of the rate at which said handpiece motor should be deaccelerated;

said motor control assembly is configured to, in response to the control signal, assert braking signals to said handpiece motor so as to cause the deacceleration of said motor; and

said processor is further configured to;

read from said memory the data representative of the rate at which said handpiece motor should be decelerated; and

if the comparison indicates that the speed of the handpiece motor is above the setpoint signal speed, apply a motor control signal that causes said motor control assembly to assert braking signals to the handpiece motor so that the handpiece motor decelerates at the rate of deceleration based on the deceleration data read from memory.

18. A surgical handpiece, said handpiece including:

a housing;

a variable speed motor disposed in said housing that is actuated in response to the application of an energization signal;

a cutting accessory for application to a surgical site that is connected to said motor for actuation by said motor;

a memory internal to said housing, said memory including data representative of the rate at which said handpiece motor should be accelerated or decelerated.

19. A powered surgical tool system, said system including:

a powered surgical handpiece, said handpiece having a variable speed motor for actuating the attachment, wherein said motor is actuated by an energization signal;

an accessory that is attached to said handpiece for application to a surgical site, said accessory being coupled to said handpiece motor for actuation by said motor;

a non-volatile memory integral with said handpiece, said memory containing data representative of a rate at which said handpiece motor should be accelerated or decelerated;

an manually set device for regulating the speed of said handpiece, said device generating a setpoint signal representative of a user selected speed for said handpiece motor; and

a control console connected to;

said handpiece for applying energization signals to said motor;

said memory for reading the data from said memory; and

to said manually set device for reading the setpoint signal, said control console being configured to;

monitor the speed of said handpiece motor;

compare the speed of said handpiece motor to the speed specified by the setpoint signal;

apply energization signals to said motor to cause said motor to run at the speed specified by the set point signal wherein said control console is further configured to apply energization signals so that said motor at least one of accelerates or decelerates to the setpoint signal speed based on the acceleration or deceleration rate data read from said memory.

20. A method of operating a powered surgical tool, said method including:

providing a surgical tool including an electrically actuated power generating unit and an accessory that is connected to and actuated by the power generating unit for application to a surgical site;

applying an electrical signal to handpiece to energize the power generating unit;

monitoring an operating state of the tool simultaneously with said step of energizing the power generating unit, wherein said monitoring is performed by a sensor and said sensor generates a sensor signal representative of the monitoring operating state;

comparing the sensor signal to a reference signal level to determine if the surgical tool is operating outside of a boundary condition for the operating state; and

if said tool is operating outside of the boundary condition for the operating state, writing data regarding the out-of-boundary condition operation of the tool to a memory integral with the tool.

21. A surgical tool system including:

a handpiece with an electrically actuated power generating unit;

an accessory attached to said handpiece for application to a surgical site, said accessory being coupled to said power generating unit for actuation by said power generating unit;

a sensor connected to said handpiece for monitoring an operating state of said handpiece, said sensor generating a sensor signal representative of the operating state;

a memory integral with said handpiece to which data can be written;

a control console, said control console including;

a socket to which said handpiece is releasably connected so that, at different times, different said handpiece can be connected to said socket;

a driver for applying energization signals to said handpiece power generating unit; and

a processor, said processor connected to;

said sensor for receiving the sensor signal; and

to said memory for writing data to said memory, said processor configured to;

compare the sensor signal to a reference signal level to determine if the handpiece is operating outside of a boundary condition for the operating state; and

if said handpiece is operating outside of the boundary condition for the operating state, writing data regarding the out-of-boundary condition operation of the tool to said memory.

22. The surgical tool system of claim 21, wherein said sensor is located in either said handpiece or said control console.

23. The surgical tool system of claim 21, wherein:

integral with said handpiece is a memory in which data defining the boundary condition of the operating parameter monitored by sensor are stored;

said processor is further configured to;

read from said handpiece memory the data regarding the data defining the boundary condition;

when comparing the sensor signal to a reference signal level, basing the reference signal level of the boundary condition data read from the memory.

24. A method of actuating a powered surgical tool, the tool including a handpiece with an electrically actuated motor and accessory that is coupled to the motor for actuation by said motor, the accessory designed for application to a surgical site, said method including the steps of:

reading from a memory integral with the handpiece data that defines for a plurality of different speeds of the handpiece motor, the maximum current the motor should draw;

applying an energization signal to said motor to actuate the motor;

monitoring the speed of the motor and the current drawn by the motor;

based on the speed of the motor and the data read from the memory, determining, for the speed of the motor, if the motor is drawing more than the maximum current for that speed; and

if the motor is drawing more than the maximum current for its speed, modulating the application of the energization signals to the motor.

25. A method of actuating a powered surgical tool, said tool including:

a handpiece with an electrically actuated power generating unit, an accessory for application to a surgical site that is attached to the handpiece and coupled to the power generating unit for actuation by the power generating unit; and

a sensor attached to said handpiece for monitoring a parameter associated with the operation of the tool, the sensor configured to generate a sensor signal representative of the monitored parameter, said method including the step of;

reading from a memory integral with the handpiece data for correcting the sensor signal;

with the sensor, sensing the parameter sensed by said parameter and reading from the sensor the sensor signal;

based on the sensor signal and the data for correcting the sensor signal, producing a corrected sensor signal;

based on the corrected sensor signal, selectively applying an energization signal to the handpiece power generating unit.

26. The method of claim 25, wherein in said step of sensing a parameter with the sensor, the parameter sensed is at least one from the group of:

a temperature associated with the handpiece; and

the actuation of a control member attached to the handpiece.

27. A surgical tool system, said system comprising:

a handpiece, said handpiece including;

a variable speed motor; and

a sensor for monitoring an operating parameter of said handpiece, the sensor configured to generate a sensor signal representative of the parameter;

an accessory for application to a surgical site, said accessory being coupled to said motor for actuation by said motor;

a memory integral with the handpiece, said memory containing data for correcting the sensor signal and that defines, for a plurality of different speeds of the handpiece motor, the maximum current the motor should draw; and

a control console, said control console including;

a socket to which said handpiece and said memory are removably connected, so that, at different times, different pairs of handpieces and memories can be connected to said socket;

a driver for generating energization signals for application to said handpiece motor through said socket;

a processor connected to said socket to receive therefrom the sensor signal and the data in said memory and to said driver for regulating the generation of energization signals by said driver, said processor configured to;

monitor the sensor signal;

based on the sensor signal and the data read from said memory, produce a corrected sensor signal;

based on the corrected sensor, regulating the generation of energization signals output by said driver for application to said handpiece motor;

monitor the speed of said handpiece motor;

monitor the current drawn by said handpiece motor;

calculate a maximum allowed current to be drawn by said handpiece motor based on the speed of said motor and the data read from said memory regarding defining the maximum allowed currents for said handpiece motor; and

if the comparison of the current drawn by said handpiece motor indicates the motor is drawing more than the maximum allowed current, regulating the generation of energization signals by said driver for application to said motor so that less than maximum allowed current is drawn by said motor.

28. A powered surgical tool system including:

a powered surgical handpiece including a variable speed motor;

an accessory for application to a surgical site, said attachment being coupled to said motor;

a non-volatile memory integral with said handpiece, said handpiece containing data about the ratio of gears in said handpiece between said motor and said attachment;

a control console connected to said handpiece for applying energization signals to said handpiece motor, said control console including;

a socket to which said surgical handpiece is removably attaches so that, at different times, different said handpieces can be connected to said socket;

a display; and

a processor, said processor configured to

read the data in said memory;

monitor the speed of said handpiece motor; and

based on the handpiece motor speed and the gear ratio data read from said memory, present on said display data regarding the speed of said accessory.

29. A powered surgical tool system including:

a surgical handpiece with an electrically actuated power consuming unit and a sensor that draws a current;

an accessory for application to a surgical site, said accessory coupled to said power consuming unit for actuation by said power consuming unit;

a memory integral with said handpiece, said memory containing data defining at least one boundary of the current drawn by said sensor; and

a control console for applying an energization signal to said handpiece power generating unit and a current to said handpiece sensor, said control console being configured to;

read the data in said memory;

monitor the current drawn by said handpiece sensor;

compare the current drawn by said handpiece sensor to boundary specified by the data read from said memory; and

if the comparison indicates that the current drawn by said sensor is outside of the specified boundary, inhibit the application of energization signals to said handpiece power generating unit.

30. A powered surgical handpiece including:

a housing;

an electrical power consuming unit located within said housing;

a surgical attachment designed for application to a surgical site that is connected to said power consuming unit for actuation by said power consuming unit;

a sensor disposed in said housing for monitoring an operating parameter of said handpiece, said sensor configured to draw a current and produce an output signal as a function of the parameter monitored by said sensor; and

a non-volatile memory integral with said housing, said memory including data indicating at least one boundary of the current drawn by said sensor.