Systems, devices and methods for pump motor fail-safe

Abstract

A pump failsafe device for use with a pump motor may be provided, the pump failsafe device including a foot pedal configured to generate a first signal when depressed and a second signal when released. The device may include a power supply having an internal logic-controlled power switch, the power supply in electrical communication with at least the pump motor, the internal logic-controlled power switch having an active state (ON) and an inactive state (OFF). The device may further include an overspeed detector, a voltage drop detector in electrical communication with at least the power supply, the voltage drop detector configured to measure a logic voltage, and a pump cartridge detector.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to medical devices, and more particularly to a pump failsafe arrangement for use with medical devices that utilize a pump motor. [Background technology]

[0002] Priority claim This application claims priority from U.S. Provisional Patent Application No. 63 / 111,137, filed November 9, 2020, the contents of which are incorporated herein by reference.

[0003] Introduction Pumps and pumping technology have been used for a variety of purposes almost since the beginning of civilization. In 2000 BC, the Egyptians used very primitive pumping systems that were no more sophisticated than the buckets used to raise water from wells. Today, modern industry has advanced and used pumping technology in a myriad of complex ways.

[0004] In particular, modern pumps are widely used in the fields of medical treatment and medical research. Medical professionals often need to quickly and effectively remove harmful substances from a patient's body. In such cases, a mechanical device, such as a pump, is needed. An advantage of many pumps used in hospitals and research facilities is that they remove materials quickly and accurately. Furthermore, the return pipes of these pumps safely and quickly siphon unwanted materials into a waste collection system where they can be properly disposed of.

[0005] Although pump technology has advanced significantly since the time of the ancient Egyptians, modern pumps have many flaws. It is often very difficult to regulate the speed at which a pump and its motor operate. Thus, one pump may be too powerful for one application and too weak for another.

[0006] Additionally, many modern pumps leave the operator with the difficult task of trying to precisely position the pump inlet, possibly inside the human body, while the pump is still pumping vigorously. The operator must exercise extreme caution when placing the pump inlet at the target location, as the pump is effectively operating at a speed that removes desired or unwanted material near the pump inlet.

[0007] Additionally, pumps that move fluids must be primed before use and between uses. As a result, it is a burden for the operator to turn the pump off and then restart suction. Typically, an operator may turn the pump off and then position the pump inlet correctly to avoid removing too much of the desired material. However, by turning the pump off, the operator may cause the pump to lose the pressure differential that causes it to suction. Therefore, the pump must be both primed and powered on when the pump inlet is in the proper location. This often leads to violent jerks of the pump or pump inlet when the pump both self-primes and powers on.

[0008] It would therefore be desirable to provide a system and method that counters many of the shortcomings of modern pumps, especially for use in precision operations. It would further be desirable to provide a pump fail-safe device that reduces the pump speed to a non-clinically relevant speed when the operator is in the process of correctly positioning the pump inlet.

[0009] It would further be desirable to provide a fail-safe device for the pump that includes multiple components designed to prevent malfunction of the pump by monitoring and shutting off power when temperature or voltage are outside acceptable thresholds. Summary of the Invention

[0010] The disclosed invention may be a pump fail-safe device for use with a pump motor, the pump fail-safe device including a pump cartridge configured to connect to the pump motor and a foot pedal configured to generate a first signal when depressed by a user and generate a second signal when released by the user. The device may further include a power supply including an internal logic-controlled power switch, the power supply in electrical communication with at least the pump motor, the internal logic-controlled power switch having an active state (ON) and an inactive state (OFF), the active state and the inactive state being switchable. The device may further include an overspeed detector in electrical communication with at least the pump motor and a Hall position sensor, the overspeed detector configured to generate a first overspeed signal and further configured to generate a second overspeed signal, and a voltage drop detector in electrical communication with at least the power supply, the voltage drop detector configured to measure a logic voltage and further configured to generate a voltage drop disable signal. In one embodiment, the device includes a pump cartridge detector in electrical communication with at least the pump cartridge, the pump cartridge detector configured to generate a positive pump cartridge signal and further configured to generate a negative pump cartridge signal.

[0011] The incorporated drawings, which are incorporated in and constitute a part of this specification, illustrate aspects of the disclosure and, together with the description, explain and illustrate the principles of the disclosure. [Brief explanation of the drawings]

[0012] [Figure 1] 1 illustrates a block diagram of a distributed computer system in which one or more aspects of an embodiment of the present invention may be implemented. [Figure 2] 1 illustrates a block diagram of an electronic device in which one or more aspects of an embodiment of the present invention may be implemented. [Figure 3]1 illustrates a circuit diagram of a fail-safe device for a pump, according to various embodiments of the present disclosure. [Figure 4] 1 illustrates a circuit diagram of a fail-safe device for a pump, according to various embodiments of the present disclosure. [Figure 5] 1 illustrates one embodiment of a pump failsafe apparatus for use with a medical device. DETAILED DESCRIPTION OF THE INVENTION

[0013] For purposes of this disclosure, singular words should be construed as including their plural meanings unless expressly stated otherwise. Additionally, the term "including" is not limiting. Furthermore, "or" is equivalent to "and / or" unless expressly stated otherwise. Ranges may be defined as preferred, but unless expressly stated otherwise, there may be embodiments that operate outside the preferred ranges.

[0014] It should be noted that the description herein is not intended to be an extensive overview, and thus concepts may be simplified for clarity and conciseness. All documents described in this application are incorporated herein by reference in their entirety. Any process described in this application may be performed in any order, and any of the process steps may be omitted. A process may also be combined with other processes or steps of other processes.

[0015] FIG. 1 illustrates components of one embodiment of an environment in which the present invention may be implemented. Not all components are required to practice the present invention, and variations in the arrangement and type of components may be made without departing from the spirit or scope of the present invention. As illustrated, system 100 includes one or more local area networks (“LAN”) / wide area networks (“WAN”) 112, one or more wireless networks 110, one or more wired or wireless client devices 106, mobile or other wireless client devices 102-105, and servers 107-109, which may include or communicate with one or more data stores or databases. The various client devices 102-106 may include, for example, desktop computers, laptop computers, set-top boxes, tablets, mobile phones, smartphones, smart speakers, wearable devices (e.g., Apple Watches), etc. The servers 107-109 may include, for example, one or more application servers, content servers, search servers, etc. FIG. 1 also illustrates an application hosting server 113.

[0016] 2 illustrates a block diagram of an electronic device 200 capable of implementing one or more aspects of an apparatus, system, and method for increasing user engagement (an "engine") for a mobile application, according to an embodiment of the present invention. An example of the electronic device 200 may include a server, e.g., servers 107-109, and client devices, e.g., client devices 102-106. Generally, the electronic device 200 may include a processor / CPU 202, memory 230, a power supply 206, and input / output (I / O) components / devices 240, such as a microphone, speaker, display, touchscreen, keyboard, mouse, keypad, microscope, GPS components, camera, heart rate sensor, light sensor, accelerometer, target biometric sensors, etc., which may be operable to provide, for example, a graphical user interface or a text user interface.

[0017] A user may provide input via a touchscreen of electronic device 200. The touchscreen may determine whether a user is providing input by determining whether the user is touching the touchscreen with a part of the user's body, such as the user's finger. Electronic device 200 may also include a communication bus 204 that connects the aforementioned elements of electronic device 200. Network interface 214 may include a receiver and a transmitter (or transceiver), as well as one or more antennas for wireless communication.

[0018] Processor 202 may include any type of processing device, such as one or more of a central processing unit (CPU) and a graphics processing unit (GPU). Also, for example, a processor may be central processing logic or other logic for performing one or more functions or operations or causing one or more functions or operations from one or more other components, and may include hardware, firmware, software, or a combination thereof. Also, based on the desired application or needs, the central processing logic or other logic may include, for example, a software-controlled microprocessor, discrete logic such as an application-specific integrated circuit (ASIC), a programmable / programmed logic device, a memory device containing instructions, or the like, or combinational logic embodied in hardware. Furthermore, logic may also be embodied entirely as software.

[0019] Memory 230, which may include random access memory (RAM) 212 and read-only memory (ROM) 232, may be enabled by any type of memory device, such as one or more of a primary storage device (directly accessible by the CPU) or a secondary storage device (indirectly accessible by the CPU) (e.g., flash memory, magnetic disk, optical disk, etc.). RAM may include operating system 221, data storage 224, which may include one or more databases, and programs and / or applications 222, which may include, for example, software aspects of program 223. ROM 232 may also include the electronic device's basic input / output system (BIOS) 220.

[0020] The software aspects of program 223 are intended to broadly include or represent all programming, applications, algorithms, models, software, and other tools necessary to implement or facilitate methods and systems according to embodiments of the present invention. Elements may reside on a single computer or may be distributed across multiple computers, servers, devices, or entities.

[0021] The power supply 206 includes one or more power components and facilitates the supply and management of power to the electronic device 200 . Input / output components, including input / output (I / O) interface 240, may include any interface for facilitating communication between, for example, any component of electronic device 200, components of external devices (e.g., components of a network or other devices in system 100), and an end user. For example, such components may include a network card, which may be an integration of a receiver, a transmitter, a transceiver, and one or more input / output interfaces. For example, a network card may facilitate wired or wireless communication with other devices in a network. In the case of wireless communication, an antenna may facilitate such communication. Additionally, I / O interface 240 and portions of bus 204 may facilitate communication between components of electronic device 200, and in one example, may facilitate processing performed by processor 202.

[0022] When electronic device 200 is a server, it may include a computing device that can transmit or receive signals, e.g., over a wired or wireless network, or that can process or store signals in memory, e.g., as physical memory states. The server may be an application server that includes configurations for providing one or more applications, e.g., aspects of the engine, to another device over a network. The application server may also host a website that can, e.g., provide a user interface for management of exemplary aspects of the engine.

[0023] Any computing device capable of transmitting, receiving, and processing data over a wired and / or wireless network may function as a server, such as in facilitating implementation aspects of the engine. Accordingly, devices functioning as servers may include devices such as dedicated rack-mounted servers, desktop computers, laptop computers, set-top boxes, integrated devices that combine one or more of the foregoing devices, etc.

[0024] Servers can vary widely in configuration and capabilities, but generally include one or more central processing units, memory, mass data storage, a power source, wired or wireless network interfaces, input / output interfaces, and an operating system such as Windows Server, Mac OS X, Unix, Linux, or FreeBSD.

[0025] A server may include a device configured to provide, or including a configuration for providing, data or content to another device over one or more networks, such as, for example, to facilitate aspects of the exemplary apparatus, system, and method of the engine. One or more servers may be used, for example, in hosting a website, such as the website www.microsoft.com. One or more servers may host a variety of sites, such as, for example, business sites, information sites, social networking sites, educational sites, wikis, financial sites, government sites, personal sites, etc.

[0026] The server may also provide a variety of services, such as, for example, web services, third-party services, audio services, video services, email services, HTTP or HTTPS services, instant messaging (IM) services, short message service (SMS) services, multimedia messaging service (MMS) services, file transfer protocol (FTP) services, voice over IP (VOIP) services, calendar services, telephone services, etc., all of which may operate in conjunction with exemplary aspects of exemplary systems and methods for devices, systems, and methods embodying the engine. The content may include, for example, text, images, audio, video, etc.

[0027] In exemplary aspects of apparatus, systems, and methods embodying the engine, client devices may include, for example, any computing device capable of transmitting and receiving data over a wired and / or wireless network. Such client devices may include desktop computers and portable devices such as mobile phones, smartphones, display pagers, radio frequency (RF) devices, infrared (IR) devices, personal digital assistants (PDAs), handheld computers, GPS-enabled devices, tablet computers, sensor-equipped devices, laptop computers, set-top boxes, wearable computers such as APPLE WATCH® and Fitbit, integrated devices that combine one or more of the foregoing devices, etc.

[0028] Client devices, such as client devices 102-106, that may be used in exemplary apparatus, systems, and methods embodying the engine may range widely in terms of capabilities and features. For example, a cell phone, smartphone, or tablet may have a numeric keypad and a few lines of monochrome liquid crystal display (LCD) display on which only text may be displayed. In another example, a web-enabled client device may have a physical or virtual keyboard, data storage (such as flash memory or an SD card), an accelerometer, a gyroscope, a respiration sensor, a body motion sensor, a proximity sensor, a motion sensor, an ambient light sensor, a moisture sensor, a temperature sensor, a compass, a barometer, a fingerprint sensor, a face recognition sensor using a camera, a pulse sensor, a heart rate variability (HRV) sensor, a beats per minute (BPM) heart rate sensor, a microphone (sound sensor), a speaker, GPS or other location-awareness capabilities, and a two-dimensional or three-dimensional touch-sensitive color screen on which both text and graphics may be displayed. In some embodiments, multiple client devices may be used to collect a combination of data. For example, a smartphone may be used to collect movement data via an accelerometer and / or gyroscope, and a smartwatch (such as an APPLE WATCH®) may be used to collect heart rate data. Multiple client devices (such as a smartphone and a smartwatch) may be communicatively coupled.

[0029] For example, client devices such as client devices 102-106 that may be used in exemplary apparatus, systems, and methods implementing the engine may run a variety of operating systems, including personal computer operating systems such as Windows, iOS, or Linux, and mobile operating systems such as iOS, Android, or Windows Mobile. The client devices may be used to run one or more applications configured to send or receive data from another computing device. Client applications may provide and receive text content, multimedia information, and the like. Client applications may perform operations such as browsing web pages, using web search engines, interacting with various apps stored on the smartphone, sending and receiving messages via email, SMS, or MMS, playing games (such as fantasy sports leagues), receiving advertisements, watching locally stored or streamed videos, or participating in social networks.

[0030] In exemplary aspects of apparatus, systems, and methods implementing the engine, one or more networks, such as network 110 or 112, may couple servers and client devices with other computing devices, including coupling to client devices through a wireless network. The network may use any form of computer-readable media for communicating information from one electronic device to another. The computer-readable media may be non-transitory. The network may include a local area network (LAN), a wide area network (WAN), a direct connection such as through a universal serial bus (USB) port, other forms of computer-readable media (computer-readable memory), or any combination thereof, as well as the Internet. In a set of interconnected LANs, including those based on different architectures and protocols, a router serves as a link between the LANs, allowing them to transmit data to one another.

[0031] Communications links within a LAN may include twisted pair wires or coaxial cables, while communications links between networks may utilize analog telephone lines, cable lines, optical lines, fully or partially dedicated digital lines including T1, T2, T3, and T4, Integrated Services Digital Networks (ISDN), Digital Subscriber Lines (DSL), wireless links including satellite links, fiber optic links, or other communications links known to those skilled in the art. Additionally, remote computers and other associated electronic devices may be remotely connected to either a LAN or a WAN via modems and telephone links.

[0032] A wireless network, such as wireless network 110, may couple devices to the network, such as exemplary apparatus, systems, and methods implementing the engine. The wireless network may use a standalone ad-hoc network, a mesh network, a wireless LAN (WLAN) network, a cellular network, etc.

[0033] A wireless network may further include autonomous systems of terminals, gateways, routers, etc., connected by wireless radio links, etc. These connectors may be configured to move freely and randomly and organize themselves arbitrarily, so that the topology of the wireless network can change rapidly. A wireless network may further employ multiple access technologies, including second generation (2G), third generation (3G), fourth generation (4G), Long Term Evolution (LTE) radio access for cellular systems, WLAN, wireless router (WR) mesh, etc. Access technologies such as 2G, 2.5G, 3G, 4G, and future access networks may enable wide-area coverage for client devices, such as client devices with various degrees of mobility. For example, a wireless network may enable wireless connectivity through wireless network access technologies such as Global System for Mobile Communications (GSM), Universal Mobile Telecommunications System (UMTS), General Packet Radio Service (GPRS), Enhanced Data GSM Environment (EDGE), 3GPP® Long Term Evolution (LTE), LTE Advanced, Wideband Code Division Multiple Access (WCDMA®), Bluetooth®, 802.11b / g / n, etc. A wireless network may include virtually any wireless communication mechanism by which information may travel between a client device and another computing device, network, etc.

[0034] The Internet Protocol (IP) may be used to transmit data communication packets over a network of participating digital communication networks and may include protocols such as TCP / IP, UDP, DECnet, NetBEUI, IPX, and AppleTalk. Versions of the Internet Protocol include IPv4 and IPv6. The Internet includes local area networks (LANs), wide area networks (WANs), wireless networks, and long-haul public networks that may allow packets to be communicated between local area networks. Packets may be transmitted between nodes within a network to sites, each with a unique local network address. Data communication packets may be transmitted from a user site through the Internet via access nodes connected to the Internet. Packets may be forwarded through network nodes to any target site connected to the network, provided the packet header contains the site address of the target site. Each packet communicated over the Internet may be routed through a path determined by gateways and servers, which switch the packet depending on the target address and the availability of a network path to connect to the target site.

[0035] A packet's header may include, for example, source port (16 bits), destination port (16 bits), sequence number (32 bits), acknowledgment number (32 bits), data offset (4 bits), spare (6 bits), checksum (16 bits), urgent pointer (16 bits), options (variable number of bits in multiples of 8 bits in length), padding (including a number of bits that may consist of all zeros and cause the header to end on a 32-bit boundary), etc. The number of bits for each of the above may also be higher or lower.

[0036] A "content delivery network" or "content distribution network" (CDN), as may be used in exemplary devices, systems, and methods implementing the engine, generally refers to a distributed computer system including a collection of autonomous computers linked by a network along with software, systems, protocols, and technologies designed to facilitate various services, such as the storage, caching, or transmission of content, streaming media, and applications on behalf of content providers. Such services may utilize supporting technologies, including, but not limited to, "cloud computing," distributed storage, DNS request processing, provisioning, data monitoring and reporting, content targeting, personalization, and business intelligence. A CDN may also enable an entity to operate and / or manage all or part of a third party's website infrastructure on behalf of a third party.

[0037] Peer-to-peer (i.e., P2P) computer networks rely primarily on the computing power and bandwidth of the participants in the network, rather than concentrating it on a given set of dedicated servers. P2P networks are typically used to connect nodes, primarily through ad-hoc connections. A pure peer-to-peer network does not have a concept of client or server, but rather has only equal peer nodes that simultaneously function as both "clients" and "servers" with other nodes on the network.

[0038] Embodiments of the present invention include apparatus, systems, and methods for implementing the engine. Embodiments of the present invention may be implemented in one or more of client devices 102-106 communicatively coupled to a server, including servers 107-109. Additionally, client devices 102-106 may be communicatively coupled (wirelessly or via wire) to one another. In particular, software aspects of the engine may be implemented in program 223. Program 223 may be implemented in one or more client devices 102-106, one or more servers 107-109 and 113, or a combination of one or more client devices 102-106 and one or more servers 107-109 and 113.

[0039] 3 illustrates a circuit diagram of a pump failsafe device, according to one embodiment. In this embodiment, the pump failsafe device may be used in conjunction with a medical device that utilizes a pump or similar device. However, in alternative embodiments, the pump failsafe device is not limited to use with only medical devices. Furthermore, the pump failsafe device may be combined with any number or type of pumps and / or motors.

[0040] In one embodiment, the pump failsafe devices include a foot pedal 302, an overspeed detector 304, a voltage drop detector 306, a power supply 308, a BLDC motor driver 310, a BLDC motor 312, an over-temperature switch 314, and / or a Hall position sensor 316.

[0041] In a further embodiment, the footswitch 302 is a pedal that can be depressed and / or released by a user. Alternatively, the footswitch 302 can be replaced by a switch operated by a user's hand, a pressure-sensitive mat, a voice command device, or any other controller capable of generating at least two signals. In a further alternative embodiment, the pump failsafe system can include one or more footswitches 302. In this further alternative embodiment, the one or more footswitches 302 can be operable by more than one user, can generate different signals, or can be in direct electrical communication with different components of the pump failsafe system. Alternatively, the function of the footswitch 302 can be realized by a button located directly on the surface of a device connected to the host machine.

[0042] In one embodiment, the footswitch 302 may generate any suitable number of signals, such as two signals. A first signal may be generated when the user presses down on the footswitch. A second signal may be generated when the user releases the footswitch. However, alternative embodiments exist in which there are more than two signals. In further embodiments, the first signal and / or the second signal may be generated when the user "double-clicks" the foot pedal 302. Alternatively, the first signal and / or the second signal may be generated when the user presses down on the foot pedal 302 for a predetermined period of time.

[0043] Additionally, in one embodiment, the foot pedal 302 allows the pump motor to be operated by a computer. In one embodiment, when the foot pedal 302 is depressed, a first signal is generated and sent to the overspeed detector 304. The first signal may disable the overspeed detector 304. In some embodiments, the first signal immediately disables the overspeed detector 304. However, in other embodiments, when a user presses down on the foot pedal 302, the foot pedal 302 sends the first signal with a delay so that the overspeed detector 304 is disabled, but not immediately. In different embodiments, this can be achieved in a variety of ways, including, but not limited to, a delay switch embedded in the foot pedal 302, an additional component disposed between the foot pedal 302 and the overspeed detector 304, or a delay switch embedded in the overspeed detector 304. However, alternative embodiments exist in which the overspeed detector 304 is immediately disabled. The delay can be configured to allow the pump to return to a specific position. For example, the delay can be configured so that upon actuation of the foot pedal, the piston has a sufficient period of time to return to an appropriate resting state (e.g., top dead center [TDC] or bottom dead center [BDC]).

[0044] In one embodiment, the pump fail-safe system includes an overspeed detector 304, which, for purposes of this embodiment, is the first component that the foot pedal 302 communicates with. In one embodiment, the overspeed detector 304 is also in communication with a Hall position sensor 316. In an alternative embodiment, the pump fail-safe system includes two or more Hall position sensors 316.

[0045] In one embodiment, the overspeed detector 304 utilizes a Hall position sensor 316 to measure the pump motor speed. In one embodiment, the overspeed detector 304 is configured at a speed below a clinically relevant speed. The pump speed can be selected by selecting a number from 1 to 10 on the user interface. Each number can be associated with the following specified speeds: 390 TPM (thrusts per minute), 490 TPM, 590 TPM, 690 TPM, 790 TPM, 862 TPM, 934 TPM, 1004 TPM, 1078 TPM, and / or 1150 TPM, or any suitable variation thereof. In some embodiments, a clinically irrelevant speed of 60 TPM is used to index the transmission at top dead center to facilitate loading and locking of the pump cartridge. The speed at which fault detection is initiated can be approximately 100 TPM.

[0046] A clinically relevant speed may be the speed of the pump motor required to allow a tool attached to the pump to adequately push fluid, adequately pump waste, or otherwise perform an operation in a manner that allows a user to use the medical device for its intended purpose. Conversely, a non-clinically relevant speed may be the speed of the pump motor when the connected tool / handpiece is receiving power, fluid, or pressure but is not operating at a level sufficient to accomplish the purpose of the underlying device.

[0047] For example, in an embodiment in which the pump motor is connected to a medical siphon, a clinically relevant speed would allow tissue to be sucked up from the body, while a non-clinically relevant speed would maintain some suction, but not enough to effectively remove tissue. However, in alternative embodiments, the clinically relevant speed, non-clinically relevant speed, and speed limits may be determined by the user and may vary depending on the associated device. However, a non-clinically relevant speed may allow the pump to continue to operate, but the function of the handpiece / tool ​​may be less noticeable.

[0048] In embodiments where suction never completely stops, there is no need to reprime the pump, and neither the pump nor the pump inlet experiences the violent jerks associated with starting an unprimed pump. However, there are embodiments in which the user can manually prime the pump. In alternative embodiments, the user can prime the pump by depressing or releasing the foot pedal 302 or by activating another button, lever, or switch. In further embodiments, the pump failsafe device may include an additional component configured to detect when the pump should be primed. The device may automatically prime the pump when a sensor detects that the pump is not primed. In such embodiments, the priming sensor may be in communication with a computer, processor, pump motor, or another component configured to prime the pump.

[0049] In one embodiment, there is a priming identification built into the system. When the user begins the procedure, the software prompts the user to first prime the unit. The system may not allow the user to proceed until it is confirmed that the pump is primed. The system may identify whether the pump is primed by monitoring the electrical system. For example, the act of priming or operating a previously primed pump may cause a higher voltage. Thus, the system may be configured to determine when the voltage profile indicates a primed or unprimed pump. For example, when the pump is primed, it may draw a reduced voltage level. Thus, the system may use the drawn motor voltage to determine whether the pump is primed. A warning to the user may be displayed on the computer monitor or device interface.

[0050] Additionally, one embodiment includes a pump cartridge detector that determines whether the pump cartridge is in proper communication with the pump motor or other components of the host device. In one embodiment, the pump cartridge detector is configured to determine when the pump cartridge is in a position that enables the automatic locking process.

[0051] Locking the pump cartridge in place can incorporate multiple steps. In some embodiments, the position of the piston within the pump cartridge is initialized at the time of manufacture but cannot be guaranteed. The first step can be to push the pump cartridge piston into a known location. This can be accomplished, for example, by first positioning the transmission at top dead center (piston fully compressed) before the pump cartridge is inserted. The pump motor can then rotate at 60 TPM until the indexing sensor detects the proper position. When the pump cartridge is inserted, the piston can bottom out first on the transmission drive shaft. Optical sensors can be mounted in an array at the entrance to the transmission specific to detecting the location and movement of the pump cartridge. The optical sensors can be coupled with software to detect the movement of the cartridge into the nest. If the piston position is not fully compressed and the cartridge movement is stalled, the user interface can instruct the user to continue pushing the pump cartridge and compressing the piston until the piston is fully compressed and the mechanical locking features match the attributes of the pump cartridge. Two mechanical attributes can hold the pump cartridge in place. The first feature may be a guillotine that holds the cartridge body (cylinder) in a fixed position. The guillotine can take all of the compression force of the pump. The comb can lock the piston shaft to the transmission drive shaft. In some embodiments, a slot in the piston shaft, a hole in the transmission drive shaft, and a pin in the comb must align for the comb to slide into the locked position. In some embodiments, force during pumping is applied to the comb only when the piston is retracted, such as when fluid is being drawn from the fluid source.

[0052] Additionally, when the pump cartridge detector detects that the pump cartridge is in a position that enables the automatic locking process, the pump cartridge detector generates a positive signal. Additionally, in one embodiment, when the pump cartridge detector does not detect that the pump cartridge is in the proper position, the pump cartridge detector generates a negative signal.

[0053] In one embodiment, a positive signal from the pump cartridge detector allows the pump motor to function, the power supply 308 to distribute power to other components, or the device to function in some other manner. In a further embodiment, the pump cartridge detector operates with a delay so that a negative signal does not immediately stop the pump motor. In one embodiment, a negative signal from the pump cartridge detector stops the pump motor gradually or with a delay.

[0054] For purposes of this disclosure, references to "stopping" the motor may refer to slowing the motor speed to a non-clinically relevant speed or stopping it completely. For example, an active state may refer to the pump motor operating at a clinically relevant speed, and an inactive state may refer to the pump motor operating at a non-clinically relevant speed.

[0055] In one embodiment, the overspeed detector 304 is enabled by a second signal (e.g., the foot pedal 302 is released) and a positive signal from the pump cartridge detector (e.g., the pump cartridge is properly communicating with the pump, pump motor, or host device). However, alternative embodiments exist in which the pump fail-safe system operates without a pump cartridge detector. In embodiments including a pump cartridge detector, the pump cartridge detector may determine proper installation of the pump cartridge via a pressure switch, an electrical switch, an infrared sensor, or other proximity sensor. In one embodiment, the pump cartridge detector is an optical sensor. Additionally, in one embodiment, the operator is notified of the position of the pump cartridge. The position of the pump cartridge may be relative to a nest containing a locking mechanism. The optical sensor and software may monitor the movement of the cartridge as it is inserted into the nest and determine whether it is in the proper position for locking. If the optical sensor detecting the barrel of the pump cartridge is blocked, a fault circuit may be enabled independent of the lock. This feature may allow the pump to be operated independent of the handpiece cartridge being in position 318.

[0056] In one embodiment, if the overspeed detector 304 operates improperly or otherwise senses an error, the user may reset the overspeed detector 304 by again depressing the foot pedal 302 (first signal). Also, in one embodiment, the overspeed detector 304 receives power and / or communication from the over-temperature switch 314. In a particular embodiment, the device is specifically configured to operate in ambient temperatures between 4 and 38°C. The motor over-temperature switch 314 may be set to 75°C. A secondary thermistor may be used by the computer to monitor the motor temperature. While the over-temperature switch 314 may be located anywhere within the pump failsafe system, in one embodiment, the over-temperature switch 314 may be connected to the system logic power so that power is shut off if the motor is overheating. However, there may be embodiments in which the pump failsafe system does not require the over-temperature switch 314. In alternative embodiments, the over-temperature switch 314 may detect the temperature of other components of the pump failsafe system, such as the pump cartridge or the power supply 308.

[0057] A system may include any number of thermistors and / or temperature sensors. For example, one temperature sensor may be configured to monitor motor temperature, another temperature sensor may be configured to monitor ambient temperature, and another temperature sensor may be configured to monitor logic temperature. Thus, each temperature sensor and / or thermistor may be associated with a location or system component, and each sensor and / or thermistor may have a different threshold temperature. For example, the motor temperature may have a threshold temperature that is higher than the ambient temperature.

[0058] Additionally, in one embodiment, the pump fail-safe device includes a voltage drop detector 306. The voltage drop detector 306 may monitor a logic voltage. Referring to FIG. 4, this may be measured by a logic supply of Ul1.3.3 volts, which may pass through the motor over-temperature switch 314. When the motor over-temperature switch 314 is conducting Ul1, the supply monitoring IC may monitor the supply voltage. For purposes of various embodiments, if the logic voltage drops below the voltage required for proper operation, the voltage drop detector 306 generates a signal to shut down the pump, motor, or power supply. In various embodiments, the voltage drop detector 306 shuts down the pump in various ways, including, but not limited to, sending a signal to the power supply 308 to turn off the pump or operate the pump at a non-clinical speed, sending a signal to the power supply 308 to instruct the power supply to no longer send power to the pump motor, or sending a signal to another component (e.g., a computer and / or processor) located between the power supply 308 and the pump motor that can interrupt the flow of power.

[0059] In some embodiments, the power supply 308 is an AC / DC power supply. However, in alternative embodiments, various commonly known power supplies may be used. In many embodiments, the power supply 308 further includes an internal logic-controlled power switch. In one embodiment, the internal logic-controlled power switch may enable and disable power output by the power supply 308. Furthermore, the internal logic-controlled power switch may disable power flow from the power supply 308 when both the overspeed detector 304 and the undervoltage detector 306 generate signals. In such an embodiment, for example, the power supply 308 may output power when the pump motor is operating below its speed limit and the logic temperature is below an approved threshold. However, in alternative embodiments, a positive signal from only one detector (e.g., detectors 304 / 306 / 314) may be sufficient to activate the internal logic-controlled power switch.

[0060] One embodiment also includes a brushless direct current motor ("BLDC") 312 and a BLDC motor driver 310. In such an embodiment, the BLDC motor driver 310 applies power to the BLDC 312 from the power supply 308. However, other embodiments exist in which the pump's fail-safe system includes a brushed DC motor. In one embodiment, the BLDC motor driver 310 includes the necessary logic to convert signals from the computer speed signal and from the Hall position monitor 316 into an AC voltage that drives the pump motor. In many embodiments, the computer speed signal is a signal that indicates the operating speed of the pump motor. The computer speed signal may originate elsewhere in the apparatus, elsewhere in the host device, or the computer speed signal may be input directly by a user.

[0061] In other embodiments, the pump failsafe device includes a tool / handpiece sensor. In some embodiments, the tool sensor is configured to determine the type of tool receiving fluid or power from the pump. For example, in one embodiment, the tool sensor determines whether a siphon or powered cutting tool is connected to the pump. In a further embodiment, the tool sensor determines whether the tool is properly connected to the pump. For example, in one embodiment, the tool sensor determines whether a powered cutting tool is seated flush with the tubing or handpiece connection interface.

[0062] In embodiments, the computer or memory includes a spreadsheet populated with a list of tools / handpieces and the corresponding preferred settings for each tool. For example, in this embodiment, the spreadsheet may indicate that a particular tool requires a particular power output, pump speed, duration, or other characteristic. In a further embodiment, the memory includes computer-executable instructions that instruct the processor how to adjust the pump motor or other components of the host device to match the pump motor to the connected tool.

[0063] In further embodiments, the tool sensor may generate a signal that may be distributed to a computer or other component of the pump's failsafe system. In such embodiments, if the tool is not properly installed, this signal may instruct the computer, or directly the power supply, that the power supply should stop distributing power to the pump motor (or at least to operate at non-clinically relevant speeds) or other components of the system.

[0064] 5, the pump failsafe device may be utilized in a system having a foot pedal 302, a handpiece 502, a saline bag 504, a waste container 506, and / or a power console 508. The power console 508 may house the pump and computer components of the pump failsafe device. The foot pedal 302 and / or the handpiece 502 may be in electrical communication with the pump failsafe device, such that signals generated by the foot pedal 302 and / or the handpiece 502 may affect the operation of the pump failsafe device. However, the pump failsafe device may be used in conjunction with any number or combination of devices.

[0065] The device may include a sensor configured to determine the identity of the handpiece. For example, each handpiece may include a magnetic location on the handpiece flange, which is configured to be recognized by the console itself. The console, or a cable connecting the console to the handpiece, may include a sensor configured to read the handpiece flange or magnetic portion. Thus, depending on which handpiece is identified, the device may adjust a setting (e.g., motor speed). Such determination and adjustment may be made by software and the overall system. In further embodiments, the user may have the ability to override the system's selection and select a different motor speed setting (e.g., 1-10) via a user interface.

[0066] The disclosed invention may be a pump fail-safe device for use with a pump motor, the pump fail-safe device including a pump cartridge configured to connect to the pump motor and a foot pedal configured to generate a first signal when depressed by a user and generate a second signal when released by the user. The device may further include a power supply including an internal logic-controlled power switch, the power supply in electrical communication with at least the pump motor, the internal logic-controlled power switch having an active state (ON) and an inactive state (OFF), the active state and the inactive state being switchable. The device may further include an overspeed detector in electrical communication with at least the pump motor and a Hall position sensor, the overspeed detector configured to generate a first overspeed signal and further configured to generate a second overspeed signal, and a voltage drop detector in electrical communication with at least the power supply, configured to measure a logic voltage and further configured to generate a voltage drop disable signal. In one embodiment, the device includes a pump cartridge detector in electrical communication with at least the pump cartridge, the pump cartridge detector configured to generate a positive pump cartridge signal and further configured to generate a negative pump cartridge signal.

[0067] In one embodiment, the pump fail-safe device further comprises an over-temperature switch in electrical communication with at least the over-speed detector, the over-temperature switch configured to determine the motor temperature and instruct the device to enter an inactive state if the motor temperature exceeds a predetermined motor temperature threshold. The predetermined motor temperature threshold may be 75° C. In a further embodiment, the device includes a thermistor configured to monitor the motor temperature and / or the ambient temperature of the device or underlying device.

[0068] The pump fail-safe device further includes a handpiece sensor in electrical communication with at least the overspeed detector, the handpiece sensor configured to determine whether the handpiece is properly installed and to instruct the device to enter an inactive state if the handpiece is not properly installed. In one embodiment, a first signal generated upon depression of the foot pedal immediately disables the overspeed detector, and a second signal generated upon release of the foot pedal includes a delay, allowing the pump motor to slow down from a clinically relevant speed to a non-clinically relevant speed. In one embodiment, the pump cartridge detector is configured to determine whether the pump cartridge is in proper communication with the pump motor, the pump cartridge piston is forced to a known location by positioning the transmission at a top dead center position before fully inserting the pump cartridge, the pump motor is converted to a thrust of 60 revolutions per minute, an indexing sensor enables detection of the position of the pump cartridge piston, and / or a user interface generates a warning to the user if the piston position is not fully compressed and pump cartridge movement stops until the pump cartridge piston is fully compressed.

[0069] The pump cartridge detector can be one or more optical sensors (e.g., a series of optical sensors). In one embodiment, the pump motor is a brushless DC motor, and the pump motor is in electrical communication with a motor driver configured to transmit power from a power source to the pump motor. The motor driver can be further configured to convert the computer speed signal and the signal from the Hall position motor into an AC voltage.

[0070] While the present invention has been described in conjunction with the above embodiments, many alternatives, modifications, and variations will become apparent to those skilled in the art upon reading the foregoing disclosure. Accordingly, the embodiments of the present invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the present invention.

Claims

1. 1. A pump failsafe device for use with a pump motor, comprising: a pump cartridge configured to connect to the pump motor; a foot pedal configured to generate a first signal when depressed by a user, the foot pedal further configured to generate a second signal when released by the user; a power supply including an internal logic controlled power switch, said power supply in electrical communication with at least said pump motor; the internal logic controlled power switch includes an active state and an inactive state; a power source, the active state and the inactive state of which are switchable; an overspeed detector in electrical communication with at least the pump motor and the Hall position sensor, the overspeed detector configured to generate a first overspeed signal and further configured to generate a second overspeed signal; a brownout detector in electrical communication with at least the power supply, the brownout detector configured to measure a logic voltage and further configured to generate a brownout disable signal; a pump cartridge detector in electrical communication with at least the pump cartridge, the pump cartridge detector configured to generate a positive pump cartridge signal and further configured to generate a negative pump cartridge signal, the pump cartridge detector configured to determine whether the pump cartridge is in proper communication with the pump motor; a piston of the pump cartridge is forced to a known location by positioning a transmission driving the piston at a top dead center position where the piston is fully compressed prior to fully inserting the pump cartridge; the pump motor rotates to generate 60 thrusts per minute, and an indexing sensor is capable of detecting the position of a piston in the pump cartridge; A pump failsafe device, wherein if the piston is not in a fully compressed position and movement of the pump cartridge stops, a user interface generates a warning to the user until the piston of the pump cartridge is fully compressed.

2. 2. The pump failsafe device of claim 1, further comprising an over-temperature switch in electrical communication with at least the over-speed detector, the over-temperature switch configured to determine a motor temperature and to instruct the pump failsafe device to enter the inactive state if the motor temperature exceeds a predetermined motor temperature threshold.

3. 3. The pump failsafe device of claim 2, wherein the predetermined motor temperature threshold is 75°C.

4. The pump failsafe device of claim 2 further comprising a thermistor configured to monitor the motor temperature.

5. 2. The pump failsafe device of claim 1, further comprising a handpiece sensor in electrical communication with at least the overspeed detector, the handpiece sensor configured to determine whether a handpiece is properly attached and to instruct the pump failsafe device to enter the inactive state if the handpiece is not properly attached.

6. 2. The pump failsafe apparatus of claim 1, wherein the first signal immediately disables the overspeed detector, and the second signal generated upon release of the foot pedal includes a delay and allows the pump motor to decelerate from a first speed to a second speed.

7. 10. The pump failsafe system of claim 1, wherein the pump cartridge detector is an optical sensor.

8. 2. The pump failsafe apparatus of claim 1, wherein the pump motor is a brushless DC motor, the pump motor being in electrical communication with a motor driver, the motor driver being configured to transfer power from the power source to the pump motor.

9. 9. The pump fail-safe device of claim 8, wherein the motor driver is further configured to convert a computer speed signal and a signal from a Hall position sensor into an AC voltage.

Images