System and method for improving control response during suction

Abstract

An aspiration system for controlling aspiration pressure in an ultrasonic surgical handpiece to improve control responsiveness during aspiration includes a console containing an aspiration pump. The system includes a joint that divides an aspiration passageway into at least two flow paths. A first joint port is connected to the first flow path. A second flow path is connected to the second joint port, a third flow path is connected to the third joint port, and a fourth flow path is connected to a surgical waste container port. A first sensor senses pressure in the fourth flow path and provides a waste container pressure signal. A second sensor senses pressure in the third flow path and provides a tip pressure signal. A controller controls the positions of a first vent valve and a second vent valve, respectively, based on the waste container pressure signal and the tip pressure signal.

Description

Technical Field

[0001] [Cross - References to Related Applications] This application claims priority to U.S. Patent Application No. 62 / 735,485, filed on September 24, 2018; U.S. Patent Application No. 62 / 749,355, filed on October 23, 2018; U.S. Patent Application No. 62 / 835,224, filed on April 17, 2019; and U.S. Patent Application No. 62 / 847,545, filed on May 14, 2019. All of these are hereby incorporated by reference in their entirety.

[0002] The present disclosure generally relates to aspiration systems and methods for use with ultrasonic surgical handpieces.

Summary of the Invention

Means for Solving the Problems

[0003] One aspect of the present disclosure provides a suction system for controlling suction pressure in an ultrasonic surgical handpiece. The system comprises a suction pump and a surgical handpiece connector. The system has a suction passage that extends at least partially between the surgical handpiece connector and the suction pump. The suction passage includes a first connector, a second connector, and a joint between the surgical handpiece connector and the first connector. The joint divides the suction passage into at least two lines. A first sensor is connected to the first portion of the suction passage, located between the second connector and the suction pump. The first sensor is configured to monitor the waste container pressure and supply a waste container pressure signal. A first vent valve is connected to the first portion of the suction passage. A second vent valve is connected to the terminal end of the second portion of the suction passage, starting from the joint. The second sensor is connected to the second portion of the suction passage and is configured to monitor the suction pressure associated with the tip of an ultrasonic surgical handpiece and supply a tip pressure signal. The controller is configured to control the position of the first vent valve based on the waste container pressure signal and the position of the second vent valve based on the tip pressure signal.

[0004] A method for controlling the suction level of an ultrasonic surgical handpiece is provided. The method includes the step of driving a suction pump to generate suction pressure in the suction system, i.e., generating suction pressure at the surgical handpiece connector. Surgical waste is deposited in a surgical waste container via the connection of a suction passage. A first sensor senses a first suction pressure. The first sensor is positioned along a first portion of the suction passage extending between the waste container connector and the suction pump. A first vent valve is connected to the first portion of the suction passage. The method further includes the steps of generating a waste container pressure signal, sensing a second suction pressure with a second sensor positioned along a second portion of the suction passage extending between the surgical handpiece connector and a second vent valve, and generating a tip pressure signal. The method includes the steps of controlling the position of a first vent valve based on the waste container pressure signal and controlling the position of a second vent valve based on the tip pressure signal.

[0005] Other aspects of the present disclosure provide a suction system for controlling suction pressure in an ultrasonic surgical handpiece. The system comprises a suction pump and a surgical handpiece connector. The system includes a suction passage that extends at least partially between the surgical handpiece connector and the suction pump. The suction passage includes a first connector and a second connector for a surgical waste container. A joint is provided between the surgical handpiece connector and the first connector. The joint divides the suction passage into at least two passages. A first vent valve is connected to a first portion of the suction passage, located between the waste container connector and the suction pump. A second vent valve is connected to the end of a second portion of the suction passage, beginning at the joint. A controller is provided, configured to maintain a pressure difference by controlling the positions of the first vent valve and the second vent valve so that the pressure in the first portion of the suction passage is higher than the pressure in the second portion of the suction passage.

[0006] Further aspects of the present disclosure provide a suction system for controlling suction pressure in an ultrasonic surgical handpiece. The system comprises a suction pump. A suction passage extends at least partially between the ultrasonic surgical handpiece and the suction pump. The suction passage further includes a first connector, a second connector, and a joint between a surgical handpiece connector and the second connector, configured to be positioned in fluid communication with the ultrasonic surgical handpiece. The joint divides the suction passage into at least two lines. A first vent valve is connected to a first portion of the suction passage located between the first connector and the suction pump. A second vent valve is connected to the end of a second portion of the suction passage, extending along the suction passage from the joint to the second vent valve. The system further comprises a first sensor, a second sensor, and a controller configured to determine a first flow rate based on a first input signal received from the first sensor and a second flow rate based on a second input signal received from the second sensor. The controller is further configured to output a tip blockage signal based on the first and second flow rates, and to control the suction pump based on the tip blockage signal.

[0007] Further methods for controlling suction pressure in an ultrasonic surgical handpiece are provided. This method includes the step of driving a suction pump to generate suction pressure in a suction system. A first sensor is connected to a first portion of the suction passage, located between a first connector and the suction pump. A first vent valve is connected to the first portion of the suction passage. The first sensor senses a first suction pressure. A second sensor is connected to a second portion of the suction passage, beginning at a joint. The joint divides the suction passage into at least two lines and extends along the suction passage to a second vent valve. The second sensor senses a second suction pressure. This method further includes the step of generating a first input signal received from the first sensor and a second input signal received from the second sensor. This method includes the step of determining a first flow rate and a second flow rate, respectively, based on the first and second input signals. This method also includes the step of outputting a tip blockage signal based on the first and second flow rates, and the step of controlling the suction pump based on the tip blockage signal.

[0008] Other aspects of the present disclosure provide a suction system comprising an ultrasonic surgical handpiece, a suction pump, and a suction passage extending at least partially between the ultrasonic surgical handpiece and the suction pump. The system includes a first connector, a second connector, and a joint between the surgical handpiece connector port and the first connector. The joint divides the suction passage into at least two lines. A first vent valve is connected to a first portion of the suction passage, which is located between the first connector and the suction pump. A second vent valve is connected to the end of a second portion of the suction passage, which extends along the suction passage from the joint to the second vent valve. A first sensor is connected to the first portion of the suction passage, and a second sensor is connected to the second portion of the suction passage. The system also includes a controller configured to determine a first flow rate based on a first input signal received from the first sensor, a second flow rate based on a second input signal received from the second sensor, output a tip-clogging signal based on the first and second flow rates, and control the suction pump based on the tip-clogging signal.

[0009] Further aspects of the present disclosure provide a suction system for controlling suction pressure in an ultrasonic surgical handpiece to improve control responsiveness during suction. The suction system comprises a suction pump, a surgical waste container having a first surgical waste container port and a second surgical waste container port, and a console including joints defining a first joint port, a second joint port, and a third joint port. The first joint port is connected to a first flow path extending from the ultrasonic surgical handpiece. The second flow path is connected to the second joint port and the first surgical waste container port. The third flow path is connected to the third joint port. The fourth flow path is connected to the second surgical waste container port. A first sensor is positioned to sense pressure in the fourth flow path and is configured to monitor waste container pressure and supply a waste container pressure signal. A second sensor is positioned to sense pressure in the third flow path and is configured to sense suction pressure associated with the tip of the ultrasonic surgical handpiece and supply a tip pressure signal. A first vent valve is connected to the fourth flow path. A second vent valve is connected to a third flow path. The system also includes a controller configured to control the position of the first vent valve based on a waste container pressure signal and the position of the second vent valve based on a tip pressure signal. A suction pump is connected to a fourth flow path.

[0010] Another method is provided for controlling a suction system to improve control responsiveness during surgery. This suction system includes a suction pump, an ultrasonic surgical handpiece, a surgical waste container, a clean-side channel, and a dirty-side channel. The system also includes a fluid backflow device communicating with the clean-side channel and a clean-side ventilation mechanism communicating with the dirty-side channel. The clean-side channel is located between the suction pump and the surgical waste container, and the dirty-side channel is located between the ultrasonic surgical handpiece and the fluid backflow device. The method comprises the steps of sensing a first pressure in the dirty-side channel, sensing a second pressure in the clean-side channel, controlling the fluid backflow device based on the first pressure, and controlling the clean-side ventilation mechanism based on the second pressure.

[0011] Further aspects of this disclosure provide a suction system for controlling suction pressure in an ultrasonic surgical handpiece to improve control responsiveness during suction. The system includes a suction pump, an ultrasonic surgical handpiece, a surgical waste container, a clean-side channel, and a console with a dirty-side channel. The clean-side channel is located between the suction pump and the surgical waste container. A fluid backflow device communicating with the clean-side channel and a clean-side ventilation mechanism communicating with the dirty-side channel are provided. The dirty-side channel is located between the ultrasonic surgical handpiece and the fluid backflow device.

[0012] Further aspects of the present disclosure provide a suction system for controlling suction pressure in an ultrasonic surgical handpiece to improve control responsiveness during suction. The system includes a console fluid-connected to the ultrasonic surgical handpiece. The console comprises a controller, a suction pump, a first sensor, a fluid backflow device, a second sensor, and a cleanside ventilation mechanism. The controller is configured to control the cleanside ventilation mechanism based on an input signal from the first sensor and to control the fluid backflow device based on an input signal from the second sensor.

[0013] Further embodiments of the present disclosure provide a suction system for controlling suction pressure in an ultrasonic surgical handpiece to improve control responsiveness during suction. The system includes a console fluidly connected to the ultrasonic surgical handpiece. The console comprises a controller, a suction pump, a first venting mechanism, and a second venting mechanism. The system is configured to be positioned in communication with a surgical waste container. The controller is configured to control the first venting mechanism and the second venting mechanism in response to the suction of liquid or solid material passing through the surgical handpiece to maintain a desired pressure in the surgical waste container. [Brief explanation of the drawing]

[0014] The drawings provided here illustrate illustrative embodiments in detail. While the drawings represent schematic embodiments, they are not necessarily to scale, and certain features may be emphasized to illustrate and illustrate groundbreaking aspects of the exemplary embodiments. Furthermore, the illustrative drawings described herein are not intended to encompass, limit, or restrict the exact forms and configurations shown in the drawings and described in detail below.

[0015] The advantages of this disclosure will be readily apparent, as will be better understood by referring to the following detailed description, as they are considered in relation to the attached drawings.

[0016] [Figure 1] This shows specific components of a suction system, including an ultrasonic surgical handpiece and control console. [Figure 2] This is a schematic diagram of the components of a suction system used to remove irrigation fluid and surgical waste from a surgical site, as an example. [Figure 3] This example illustrates specific components of a suction system that distinguish between the clean and dirty sides of a flow path. [Figure 4]Exploded view of a cassette including tubes of the suction system and the cleaning system. [Figure 5A] Diagram of an assembled cassette according to an example. [Figure 5B] Diagram of an assembled cassette inserted into a control console according to an example. [Figure 6] Shows a cross-section of a pinch valve of the console aligned with a part of the suction passage of the cassette and the system. [Figure 7A] Perspective view of a specific internal component of the suction system within the console, including the pinch valve. [Figure 7B] Another perspective view of the internal components of the suction system within the console, including the controller and the suction manifold. [Figure 7C] Enlarged view of the suction manifold of the suction system within the console. [Figure 8] Top view of the suction manifold showing the pressure sensors and their connections to the suction passages. [Figure 9] Circuit diagram of an exemplary pressure sensor. [Figure 10] Block diagram of a control system including a first PID control loop and a second PID control loop used to adjust the first ventilation valve and the second ventilation valve of the suction system of FIG. 1. [Figure 11] Graphical display of the target pressure and the actual pressure at various points in the suction passage based on various suction set values. [Figure 12] Schematic diagram of a suction system using an electrical schematic connection representing air resistance as an example. [Figure 13] Shows an operation routine implemented by a suction system that determines whether a blockage has been detected within an ultrasonic surgical handpiece as an example. <T

Best Mode for Carrying Out the Invention

[0017] I. Overview of the System FIG. 1 shows certain components of the aspiration system 42. The aspiration system 42 is described for use with the ultrasonic surgical handpiece 28 and the console 20, but in certain configurations, it can also be used with other handpieces that operate by mechanical means, such as electric burs, drills, and saws. The ultrasonic surgical handpiece 28 includes an ultrasonic surgical handpiece tip 30 that aspirates the surgical site. It should be understood that aspiration includes any form of material from the surgical site. For example, the ultrasonic surgical handpiece 28 can aspirate liquid and solid materials from the surgical site through the ultrasonic surgical handpiece. Further, unless otherwise specified, "proximal" is understood to mean toward the ultrasonic surgical handpiece tip 30, and "distal" is understood to mean away from the ultrasonic surgical handpiece tip 30.

[0018] The aspiration system 42 includes a console 20 that supplies power and aspiration force to the ultrasonic surgical handpiece 28. The console 20 includes a display 22 that displays the amount of power, the amount of irrigation, the amount of aspiration, or a combination thereof. The console 20 may also be connected to a foot pedal 32, a hand switch, or any other control device that controls whether the surgical handpiece tip 30 vibrates actively when the power of the ultrasonic surgical handpiece 28 is turned on.

[0019] According to one configuration, the aspiration system 42 includes a console 20 with an aspiration pump 74, a cassette 34, and the ultrasonic surgical handpiece 28. In other configurations, the aspiration system 42 includes a surgical console 20, an aspiration pump 74, a surgical waste container 70 or other waste container, a cassette 34, and the ultrasonic surgical handpiece 28.

[0020] Figure 2 is a schematic diagram of the components of a suction system 42 for removing cleaning fluid and surgical waste from the surgical site. The console 20, surgical waste container 70, cassette 34, and / or ultrasonic surgical handpiece 28 include any number of ports / connectors, and multiple components may be fluidly connected to one another. For example, the ultrasonic surgical handpiece 28 may include an ultrasonic surgical handpiece connector 26. Multiple components of the suction system 42 are connected together with various tubes or lines to form a suction passage 40. A suction pump 74 generates suction pressure throughout the suction passage 40, thereby causing most of the surgical waste and cleaning fluid, in the form of liquid, gas, solid, or a combination thereof, to pass through the suction passage 40 and finally into the surgical waste container 70.

[0021] Cassette 34 may include a portion of the line having a suction passage 40. When cassette 34 is inserted into console 20, cassette 34 and console 20 are aligned with the first port 95, second port 96, and third port 98 of the suction manifold 36 in console 20, so that multiple lines of the suction passage 40 extend from the ultrasonic surgical handpiece 28, pinch valve 62, and filter 72 to each port, as shown in Figure 2. The surgical handpiece tip 30 is connected to a waste line 38. The waste line 38 extends from the surgical handpiece tip 30 to a joint 44 of cassette 34. The joint 44 divides the suction passage 40 into at least two flow paths, as shown in Figure 2. Unless otherwise specified, multiple lines should be understood as tubes and / or flow paths. The joint 44 may include a fluid backflow device 462. The fluid backflow device 462 allows air to pass through, but prevents surgical waste or aspirated fluid from entering the portion of the suction passage 40 beyond the fluid backflow device 462.

[0022] In one configuration, the joint 44 comprises a first joint port 440, a second joint port 442, and a third joint port 444. The surgical waste container 70 includes a first surgical waste container port 446 and a second surgical waste container port 448. The first surgical waste container connector 82 is connected to the first surgical waste container port 446, and the second surgical waste container connector 66 is connected to the second surgical waste container port 448.

[0023] Multiple channels of the suction passage 40 can be described in relation to the joint 44, the surgical waste container 70, and the suction pump 74. The first joint port 440 is connected to the first channel 450 extending from the ultrasonic surgical handpiece 28. The second channel 452 is connected to the second joint port 442 and the first surgical waste container port 446. The third channel 454 is connected to the third joint port 444, and the fourth channel 456 is connected to the second surgical waste container port 448. The fourth channel 456 extends at least partially from the second surgical waste container port 448 to the suction pump 74.

[0024] In other words, the suction passage 40 can be divided into three parts. The first part 40a of the suction passage 40 is located between the second surgical waste container connector 66 and the suction pump 74. The second part 40b of the suction passage 40 extends along the suction passage 40, starting from the joint 44, to the second vent valve 60. The second vent valve 60 can be used to open the suction passage 40 to the atmosphere, as will be described below. The third part 40c of the suction passage 40 extends at least partially from the joint 44 to the first surgical waste container connector 82.

[0025] Unless otherwise specified, please understand that the first channel 450 is associated with the waste line 38, the second channel 452 is associated with the third portion 40c of the suction passage 40, the third channel 454 is associated with the second portion 40b of the suction passage 40, and the fourth channel 456 is associated with the first portion 40a of the suction passage 40.

[0026] Additionally or alternatively, the suction passage 40 may be divided into two passages, namely a clean-side passage 458 and a dirty-side passage 460. The clean-side passage 458 is located between the suction pump 74 and the surgical waste container 70. The dirty-side passage 460 is located between the ultrasonic surgical handpiece 28 and the fluid backflow device 462. The fluid backflow device 462 is provided in communication with the dirty-side passage 460, and the clean-side ventilation mechanism 464 may be provided in communication with the clean-side passage 458. It should be understood that the clean-side ventilation mechanism 464 may be a first ventilation mechanism including a first ventilation valve 54. In some configurations, the system 42 includes a second ventilation mechanism 461 including a second ventilation valve 60. The fluid backflow device 462 can be implemented to facilitate the dissipation of suction pressure by introducing fresh air into the dirty passage 460. Referring to Figure 3, the "clean side" is free of surgical waste (e.g., tissue and bodily fluids), while the "dirty side" contains surgical waste aspirated from the surgical site. The "clean side" is between the suction pump 74 (not shown in Figure 3) and the surgical waste container 70. The "dirty side" is between the ultrasonic surgical handpiece 28 and the fluid backflow device 463 (not shown in Figure 3). In other words, in this configuration, the surgical waste container 70 can provide a functional boundary between the clean side and the dirty side of the flow path.

[0027] A combination of a fluid backflow device 462, gravity, directional suction (which tends to keep surgical waste flowing away from the fluid backflow device 462), and a dirty side channel 460 can be used to allow direct ventilation to the third section 40c and / or dirty side channel 460 via the second ventilation mechanism 461. Features of these designs ensure that surgical waste does not contaminate the second ventilation mechanism 461.

[0028] By providing multiple lines, passages, and / or sections of the suction passage 40, the advantage of this system 42 is the dual pressure regulation by a first sensor 48 and a second sensor 57. Furthermore, another advantage of this system 42 is improved control responsiveness during operation due to blockage detection. The first sensor 48 is positioned to sense the pressure in a first section 40a of the suction passage 40 and to monitor the waste container pressure. The second sensor 57 is positioned to sense the pressure in a second section 40b of the suction passage 40 and to monitor the suction pressure associated with the ultrasonic surgical handpiece tip 30. The system 42 includes a controller 102 that controls a first vent valve 54 and a second vent valve 60 based on signals from the first and second sensors 48, 57. Additionally or alternatively, a cleanside vent mechanism 464 may include the first vent valve 54. The fluid backflow device 462 may be a joint 44 including a joint valve or ball valve 86. The first and second vent valves 54 and 60, when opened, introduce air or fresh air into the system 42 to relieve the suction pressure. The dual adjustment and blockage detection by the first sensor 48 and the second sensor 57 will be described in detail below.

[0029] Dual adjustment allows system 42 to regulate the pressure in the surgical waste container 70 and the pressure at the surgical site. System 42 improves the control responsiveness during various operations of the ultrasonic surgical handpiece 28, provides a wide range of overall suction control, fine-tunes the suction setting, and enhances optimal suction performance. For example, using dual adjustment (e.g., using the first and second ventilation mechanisms) allows for significantly lower suction levels. This greatly reduces the "suction" force on the tissue. This is important for avoiding fragile tissue and provides comfort to both the patient and the surgeon.

[0030] When liquid and solid materials are aspirated from the surgical site into the waste line 38 using the ultrasonic surgical handpiece 28, the surgical waste flows through the joint 44 and pinch valve 62. In this configuration, the suction passage 40 is open to the surgical waste container 70, and gravity removes the surgical waste from the second portion 40b of the suction passage 40. The second surgical waste container port 448 is connected to the second surgical waste container connector 66, which is connected to a filter 72. The filter 72 is located proximal to the surgical waste container 70 when viewed from the console perspective. The filter 72 is designed to remove any remaining surgical waste not captured by the surgical waste container 70 from the second portion 40b of the suction passage 40. The filter 72 may also be part of the cassette assembly and / or tubing, and the filter 72 can be easily discarded and replaced after surgery. The filter 72 is connected to the console 20 via other lines through the first port 95.

[0031] Figure 4 shows an exploded view of the cassette 34. In one configuration, the cassette may be optional. In other words, the cassette 34 itself may be omitted, but the line connecting the ultrasonic surgical handpiece 28 to the surgical waste container 70 may still be included, as well as the joint 44. As shown in Figure 4, the joint 44 includes a ball valve 86, or any other type of fluid backflow device 462.

[0032] The ball valve 86 / fluid backflow device 462 is a one-way valve that allows air to pass from the second section 40b of the suction passage 40 to the third section 40c of the suction passage 40, but prevents surgical waste or suction fluid from entering the second section 40b of the suction passage 40 from the surgical handpiece tip 30. The ball valve 86 is mounted such that its ball is biased to the open position by gravity and is pushed upward to the closed position by the influence of fluid from the third section 40c of the suction passage 40. A chamber 88 is provided distal to the ball valve 86 to hold surgical waste that passes through the ball valve 86 and enters the second section 40b of the suction passage 40. The chamber 88 may have an inclined bottom. When the ball of the ball valve 86 returns to its resting position, the inclined bottom of the chamber 88 causes the surgical waste that has passed through the ball valve 86 to backflow into the third section 40c of the suction passage 40. Instead of a ball valve, any type of valve may be used to control the fluid flow in the second portion 40b of the suction passage 40.

[0033] As shown in Figures 4 to 5B, a cassette 34 is used to more easily route the irrigation and suction lines to the console 20. In this configuration, both irrigation lines 90 and 92, as well as the suction passage 40, are contained within a single cassette 34. In certain configurations, either irrigation line 90 / 92 is provided, and the ultrasonic surgical handpiece 28 can be connected to the irrigation source 91. In some configurations, the irrigation fluid line can be routed through the cassette 34 to the ultrasonic surgical handpiece connector 26. Including both the irrigation and suction lines in the same cassette 34 simplifies the setup and operation of the ultrasonic aspirator. Furthermore, pre-setting the tubing inside the cassette 34 avoids user errors that could occur, such as misalignment of the pinch valve 62 with respect to the suction passage 40.

[0034] Figures 5A and 5B show the cassette 34. The user inserts the cassette 34 into the console 20 in a single action requiring one hand. Upon completion of this single action, the cassette RFID (radio frequency identification) tag 94 is detected by the console 20. This indicates that the cassette 34 has been fully inserted. Once the cassette 34 is inserted and aligned, the pinch valve 62 can be activated. When the pinch valve 62 is activated, it compresses the tube of the third portion 40c of the suction passage 40 held in the cassette 34.

[0035] As shown in Figures 7A and 7B, the console 20 is provided with a cassette release button 500. The cassette socket 76 may include one or more sensors, such as a Hall effect sensor, a magnetic sensor, or other suitable sensor, which generate a signal in response to the pressing of the cassette release button 500. In this configuration, as shown in Figure 7B, the cassette release button 500 includes a magnet 93, and the cassette socket 76 includes a printed circuit board assembly (PCBA) 99 which includes a Hall effect sensor 89. The magnet 93 helps detect whether a cassette 34 has been inserted and / or ejected. When the cassette release button 500 is pressed, the magnet 93 moves closer to the Hall effect sensor 89, helping to detect that the cassette 34 is about to be ejected. In response, the system 42, controller 102, and / or PCBA 99 open the pinch valve 62 before the cassette 34 is ejected. This ensures that the cassette 34 is ejected properly.

[0036] As shown in Figure 5B, the cassette housing 84 includes an opening 85 above the tube defining the third portion 40c of the suction passage 40, which is aligned with the pinch valve 62. As shown in Figure 5B, when the cassette 34 is inserted into the console 20, the opening 85 of the cassette housing 84 is positioned adjacent to the pinch valve 63. As shown in Figure 6, when the pinch valve is activated, the rod 172 is used to pinch the third portion 40C of the suction passage 40. The pinch valve 62 prevents suction pressure from reaching the tip 30 of the ultrasonic surgical handpiece. More specifically, the pinch valve 62 affects the degree of occlusion in the suction passage 40 by ensuring the blocking of a high response of suction pressure at the tip 30 of the ultrasonic surgical handpiece.

[0037] The console 20 may also further include a three-way solenoid valve 64, as shown in Figure 7A. The three-way solenoid valve 64 controls the operation of the pinch valve 62. The three-way solenoid valve 64 is connected to the suction pump 74 via a first portion 40a of the suction passage 40. When the suction system 42 is activated and surgical waste is removed from the surgical handpiece tip 30, the pinch valve 62 is connected to the atmosphere by the three-way solenoid valve 64. In this configuration, the pinch valve 62 is pneumatically operated and opens and closes by moving the solenoid of the three-way solenoid valve 64, allowing the suction pressure to engage with a mechanical actuator 100, which includes the coil 170, rod 172, gasket 174, and pump head 110 of the pinch valve 62, as shown in Figure 6. In other configurations, the pinch valve 62 is electrically operated, and the three-way solenoid valve 64 is not required.

[0038] With respect to the pinch valve 62 and the three-way solenoid valve 64, the suction system 42 can operate in one or more modes, including standard mode and synchronous mode. In standard mode, the pinch valve 62 and the three-way solenoid valve 64 operate as if the foot pedal 32 were pressed to activate the surgical handpiece 28. Whenever power is turned on to the console 20, suction is performed at the tip 30 of the ultrasonic surgical handpiece in standard mode. In standard mode, the pinch valve 62 remains stationary when the pinch valve 62 is openly connected to the surgical handpiece tip 30 and the surgical waste container 70 and the suction pump 74 via the suction passage 40.

[0039] Specifically, in standard mode, the three-way solenoid valve 64 is always open to the atmosphere and closed to the suction pump 40. This allows suction pressure to reach the tip of the surgical handpiece 30, enabling suction at the surgical site. With regard to a suction system designed to be always on, the system 42 can be manufactured without the three-way solenoid valve 64 or the pinch valve 62.

[0040] A second potential operating mode for suction is the synchronous mode. In synchronous mode, if the foot pedal 32 is not pressed and the surgical handpiece tip 30 is vibrating, suction pressure is not permitted to reach the surgical site. Specifically, when the foot pedal 32 is not pressed and the ultrasonic surgical handpiece tip 30 is not vibrating, the pinch valve 62 is activated, and the connection between the surgical handpiece tip 30 and the suction pump 74 is closed. The pinch valve 62 is actuated by a three-way solenoid valve 64. When the foot pedal 32 is not pressed, the solenoid of the three-way solenoid valve 64 moves, and the pinch valve 62 is closed to the atmosphere and opened to the suction pump 40. This prevents suction pressure from reaching the surgical handpiece tip 30 and the surgical site. When the foot pedal 32 is not pressed, the second vent valve 60 also opens to the atmosphere, rapidly dissipating the suction pressure at the surgical site.

[0041] In synchronous mode, the suction system 42 functions similarly to the standard mode described above when the foot pedal 32 is pressed to activate the ultrasonic surgical handpiece 28. For example, if the pinch valve 62 is stationary, when the foot pedal 32 is pressed, the suction passage 40 opens between the tip 30 of the ultrasonic surgical handpiece and the suction pump 74.

[0042] The suction pump 74 is selectively connected to a pinch valve 62 via a three-way solenoid valve 64. The pinch valve 62 is connected to a socket 76 of the cassette 34, as shown in Figures 7A and 7B. In this configuration, the suction pump 74 uses a double diaphragm design that keeps the element of the suction pump 74 isolated from the pressurized air. The two diaphragms also supply twice the airflow of a single diaphragm for each stroke of the piston, allowing the suction pump 74 to operate at low speeds. Furthermore, in this configuration, the pump head 110 may be made of plastic to reduce mechanical pumping noise. As shown in Figure 5, the pump heads 110 are arranged in series to shorten the length of the suction passage 40. Shortening the length of the tubing near the suction pump 74 limits the possibility of the tubing vibrating and generating undesirable noise.

[0043] Figure 7B shows a suction manifold 36, which includes a first vent valve 54, a second vent valve 60, and a controller 102. Figure 7B also shows a cassette socket 76 into which the user inserts a cassette 34. As also shown in Figure 7B, the socket 76 for the cassette 34 includes an opening for a pinch valve 62. When the cassette 34 is properly inserted, the opening 85 in the cassette housing 84 aligns with the opening in the socket 76, allowing the pinch valve 62 to engage with the line of the suction passage 40.

[0044] Figures 7C and 8 are alternative enlarged views of the suction manifold 36. The suction manifold 36 includes a first sensor 48, a second sensor 57, a first vent valve 54, a second vent valve 60, and a printed circuit board 102. In this configuration, the first sensor 48, which includes a differential pressure sensor 50a and a gauge pressure sensor 52a, is available to determine a first suction pressure 180 in the surgical waste container 70 and generate a waste container pressure signal 132 measured based on the first suction pressure 180. Similarly, the second sensor 57, which includes a differential pressure sensor 50b and a gauge pressure sensor 52b, is available to determine a second suction pressure 182 at the surgical site and generate a measured tip pressure signal 133. Both of these signals are supplied to a controller 102, which is the printed circuit board 102 in this configuration, to control the first vent valve 54 and the second vent valve 60.

[0045] The suction manifold 36 helps to divide the airflow from the suction pump 74 to the suction passage 40 and the pinch valve 62. Differential pressure sensors 50a and 50b can be used to monitor the pressure or flow rate in the first section 40a and the second section 40b of the suction passage 40. Additionally or alternatively, gauge pressure sensors 52a and 52b can be used to monitor the pressure in the first section 40a and the second section 40b. The machined manifold 104 shown in Figures 7A to 7C distributes the suction flow in the first section 40a and the second section 40b of the suction passage 40 by manipulating ventilation to the atmosphere via the first vent valve 54 and the second vent valve 60, similar to any other valves or mufflers.

[0046] The main muffler 106 shown in Figures 7A to 7C reduces the pumping exhaust noise from the suction pump 74. Pulsating exhaust is one of the biggest noise sources in the system 42. In this configuration, the mechanical actuator 100 has a large cross-sectional flow path, allowing the suction pressure at the pinch valve 62 to be rapidly released into the atmosphere. This allows the pinch valve 62 to quickly return to its open position.

[0047] Figure 9 is a schematic diagram of an exemplary pressure sensor. In this example, a 15 PSI sensor is connected to a suction passage 40. Measurement of the suction passage 40 can be performed using differential pressure sensors 50a, 50b and gauge pressure sensors 52a, 52b. The first and second sensors 48, 57 output voltages representing pressure. The voltage signals are sent to an amplifier 120, which in this configuration is an operational amplifier with adjustable gain. The sensed signals then pass through a low-pass filter 122 that reduces noise from the signal. In this configuration, the low-pass filter 122 comprises a capacitor 123 and a resistor 124. Finally, the signal is processed by a rectifier 125 to generate a corrected signal. The corrected signal is also processed by a controller 102. While the processing of the sensed signals is shown to use specific hardware, it may be done using general-purpose hardware and software.

[0048] II. Double adjustment To improve control responsiveness during suction, the console 20, more specifically the suction manifold 36, includes a first vent valve 54, a first sensor 48, a second vent valve 60, and a second sensor 57. As described above, the first vent valve 54 may be associated with a clean-side vent mechanism. The first vent valve 54 is positioned along the first portion 40a of the suction passage 40, and the second vent valve 60 is positioned at the end of the second portion 40b of the suction passage 40, or proximal to the fluid backflow device 462, to adjust the suction system 42.

[0049] The console 20 may include a controller 102. The first and second sensors 48, 57 are connected to the controller 102 to provide dual adjustment of the system 42. The controller 102 is configured to control the first and second vent valves 54, 60 to adjust the suction level in the suction system 42. More specifically, the controller 102 is configured to independently control the position of the first vent valve 54 and the position of the second vent valve 60, respectively, based on the outputs of the first sensor 48 and the second sensor 57.

[0050] Adjustments to both the first vent valve 54 and the second vent valve 60 help maintain the desired suction pressure at the surgical site. In this configuration, the first vent valve 54 and the second vent valve 60 are variable flow iDP (intelligent diagnostic positioner) valves. The airflow through the first vent valve 54 and the second vent valve 40 is proportional to the current controlled by the first PID (proportional-integral-derivative) control loop 126 and the second PID control loop 128 of the controller 102. The first and second PID control loops 126 and 128 are described in detail below.

[0051] The first sensor 48 is positioned along the first portion 40a of the suction passage 40 and effectively senses the pressure in the surgical waste container 70. Furthermore, to enable faster and more responsive control, a second sensor 57 and a second vent valve 60 are included along the second portion 40b of the suction passage 40.

[0052] In this configuration, the first sensor 48 may include a differential pressure sensor 50a and / or a gauge pressure sensor 52a. In alternative configurations, various types of pressure sensors can be used. Measurements from the first sensor 48 are transmitted to the controller 102 to generate a first input signal 232, which controls the first vent valve 54 to selectively open the first portion 40a of the suction passage 40 to the atmosphere. The first input signal may be based on a first suction pressure 180. Additionally or alternatively, the first input signal 232 may be a measured waste container pressure signal 132. In other configurations, the first input signal 232 may be based on the maximum first vent current 156 or first vent current 164.

[0053] Based on the signal supplied by the first sensor 48, the first vent valve 54 may be positioned to open the suction passage 40 to the atmosphere. This reduces the suction pressure in the first portion 40a of the suction passage 40, and ultimately in the entire suction passage 40, even if the response speed is slower than the decrease in suction pressure at the tip 30 of the ultrasonic surgical handpiece 28 caused by the opening of the second vent valve 60. The first vent valve 54 may be a variable valve that operates mechanically, electrically, or pneumatically.

[0054] The combination of a first sensor 48 and a first vent valve 54 positioned along the first portion 40a of the suction passage 40 helps control the suction pressure at the surgical site. However, the control provided by the first vent valve 54 may be slow to respond to pressure changes in the system 42 due to the large-capacity surgical waste container 70, the first portion 40a of the suction passage 40, and the third portion 40c of the suction passage 40. The compliance of the first portion 40a and the third portion 40c of the suction passage 40 (expansion and contraction of the first portion 40a and the third portion 40) exacerbates the problem. This is because the lines defining portions 40a, 40b, and 40c of the suction passage 40 expand and can become even larger in response to pressure changes in the system 42.

[0055] To improve control responsiveness, the second sensor 57 and the second vent valve 60 are included along the second portion 40b of the suction passage 40. Similar to the first sensor 48, the second sensor 57 may include a differential pressure sensor 50b and / or a gauge pressure sensor 52b. The first sensor 48 and the second sensor 57 may be, but are not limited to, any type of sensor, including pressure sensors, temperature sensors, ultrasonic sensors, and gas sensors. The first sensor 48 and the second sensor 57 may comprise any number of individual sensors.

[0056] The second sensor 57 is configured to effectively sense a second suction pressure 182 at the tip 30 of the surgical handpiece. The measurement from the second sensor 57 is transmitted to the controller 102 and used to generate a second input signal 233 that controls the second vent valve 60, selectively opening the second portion 40b of the suction passage 40 to the atmosphere.

[0057] The second vent valve 60 is operable to open the suction passage 40 to the atmosphere and reduce the pressure in a location close to the suction passage 40 or the fluid backflow device 462. More specifically, the second vent valve 60 is located at the end 47 of the second portion 40b of the suction passage 40. In this configuration, the second vent valve 60 is also distal to the second sensor 57. The second vent valve 60 may be the same as or different from the first vent valve 54.

[0058] In one configuration, or during a particular mode, the suction pressure in the ultrasonic surgical handpiece 28 is fully controlled by a second vent valve 60. In this configuration, the system 42 provides a sense of lower pressure suction setpoints, thereby resulting in lower pressure at the tip 30 of the ultrasonic surgical handpiece 28, allowing the suction line between the cassette 34 and the surgical waste container 70 to be cleared more quickly while reducing blockages. The second sensor 57 allows the system 42 to monitor the pressure at the tip 30 of the surgical handpiece 28, thereby enabling the system 42 to detect potential blockages in the suction line. The measurement from the second sensor 57 may represent the pressure at the tip 30, which can be used to estimate the flow rate at the tip 30 of the surgical handpiece 28. Once the flow rate is estimated, the system 42 can detect potential blockages. When the system 42 can detect potential blockages, it helps maintain ideal conditions during surgery and optimize the required ultrasonic energy.

[0059] The second suction pressure 182 is less affected by the large-capacity surgical waste container 70, and therefore, even though the second sensor 57 is also located in the console 20, the measurement from the second sensor 57 better represents the actual pressure at the tip 30 of the ultrasonic surgical handpiece 28. Controlling the second vent valve 60 provides a faster response than controlling the first vent valve 54 when controlling the pressure at the tip 30 of the surgical handpiece. Faster control is achieved because the volume between the tip 30 of the surgical handpiece 30 and the second vent valve 60 is much smaller than the volume between the surgical waste container 70 where the first vent valve 54 is located and the first portion 40a of the suction passage 40. This is also because the second vent valve 60 is closer to the tip 30 of the ultrasonic surgical handpiece 28 compared to the large-capacity surgical waste container 70. Furthermore, since the second portion 40b of the suction passage 40 has a much smaller volume than the first portion 40a of the suction passage 40, the second portion 40b of the suction passage 40 has less conformability and is less likely to deform as a result of suction pressure.

[0060] The suction control algorithm dynamically adjusts the suction by changing the current supplied to the first vent valve 54 and the second vent valve 69 using signals representing the pressure in both the tip 30 and the surgical waste container 70, thereby changing the pressure and flow rate in the system 42.

[0061] Figure 10 is a partial block diagram of the controller 102, showing a control system 42 used to control the suction pressure in the ultrasonic surgical handpiece 28 and improve the control responsiveness of the ultrasonic surgical handpiece 28 during operation. First and second PID control loops 126, 128 are used to adjust the pressure in the suction passage 40. First and second PID controllers 152, 154 use several inputs to output a first vent current 164 and a second vent current 166, respectively, and adjust the positions of first and second vent valves 54, 60, respectively.

[0062] Signals from the first and second sensors 48, 58 supply first and second input signals 232, 233. In one configuration, the first input signal 232 is the measured waste container pressure signal 132, and the second input signal 233 is the measured tip pressure signal 133. Other inputs may include a maximum waste container pressure signal 138, a minimum handpiece pressure signal 136, a tip blockage signal, a suction setpoint 140, and a foot pedal setpoint 142. All of these are described in detail below.

[0063] By reading data from the first and second sensors 48 and 57 and interfaceing them to the first and second vent valves 54 and 60, the first and second PID control loops 126 and 128 actively change the current supply to the first and second vent valves 54 and 60, improving the system's responsiveness. In a specific configuration where the first and second sensors are flow meters, the measurements from the first and second sensors 48 and 57 allow the controller 102 to monitor the overall flow rate of the system 42 and detect any blockages that may occur in the suction line. The detection of blockages in the system 42 is described in detail below.

[0064] The first PID control loop 126 is responsible for receiving inputs regarding the pressure in the first portion 40a of the suction passage 40 and thus adjusting the suction level maintained in the surgical waste container 70. This ensures that the pinch valve 62 is operational (it is controlled by pneumatics as needed to engage using the pressure generated by the suction pump 74) and controls the maximum amount of suction available in the suction system 42 over a given time. The time scale of the pressure control response in the first portion 40a of the suction passage 40 is primarily determined by the amount of air available in the surgical waste container 70.

[0065] Referring to Figure 10, the first PID control loop 126 is implemented to control the first vent valve 54. In the first PID control loop 126, the actual pressure measurement is obtained from a first sensor 48 connected to a first portion 40a of the suction passage 40. In this example, the first sensor 48 outputs a voltage based on the measured pressure. This voltage can be converted to a pressure measurement using a voltage-to-pressure converter 130. The converted pressure signal is the measured waste container pressure signal 132.

[0066] The target waste container pressure signal 134 is determined based on the power setpoint from the console 20, as well as parameters or information that can be stored in each surgical handpiece tip 30, ultrasonic surgical handpiece 28, or the console 20. In this configuration, the target waste container pressure signal 134 is calculated from the suction setpoint 140, the minimum handpiece pressure signal 136, and the maximum waste container pressure signal 138. Once the target waste container pressure signal 134 is calculated, it is combined with the negative value of the measured waste container pressure signal 132 by a first combiner. The difference between the two signals 134 and 132 becomes the waste container pressure error signal 148. In other configurations, the target waste container pressure signal 134 may be compared, combined, summed, etc., in relation to the measured waste container error signal 132 and the waste container pressure error signal 148. The waste container pressure error signal 148 is supplied to the first PID controller 152.

[0067] Both the suction setting value 140 and the foot pedal setting value 142 are user selections entered into the console 20.

[0068] Furthermore, the first PID controller 152 receives signals indicating the maximum first venting current 156 and the minimum first venting current 158. The first PID controller 152 then outputs a first venting current 164 that opens and closes the first vent valve 54. In this configuration, the first venting current 164 is converted so that a larger current opens the first vent valve 54 more, and a smaller current closes the first vent valve 54 more.

[0069] In one configuration, two parameters, namely the maximum waste container pressure 138 and the minimum handpiece pressure 136, are stored in an RFID tag or other memory device associated with each surgical handpiece tip 30. Specifically, the RFID tag may be contained in a sleeve associated with each surgical handpiece tip 30. Additionally or alternatively, the controller 102 may include a memory device 168. It should be understood that the memory device associated with the surgical handpiece tip 30 may be the same as or different from the memory device 168 associated with the controller 102. It should be further understood that the system 42 may include any number of memory devices.

[0070] A better system is provided because many aspects of the system can be modified depending on the surgical handpiece tip 30 used, by storing the maximum waste container pressure 138 and the minimum handpiece pressure 136 in the surgical handpiece tip 30 or the sleeve associated with each tip. The maximum pressure achievable by the system is defined by the rate at which the suction pressure is released. Each surgical handpiece tip 30 has different suction characteristics, thereby having different steady-state pressures when the first vent valve 54 and the second vent valve 60 are fully open and / or fully closed. Each surgical handpiece tip 30 can have different lengths, different pre-aspiration hole configurations, different sleeve sizes, and different geometric shapes. This results in absolute minimum and absolute maximum setpoints. To control across the entire range available for each different tip, an RFID tag or other memory device holds two parameters used in the suction control system: the maximum waste container pressure 138 that the control system allows, and the minimum tip pressure 136 that the control system allows. The maximum waste container pressure signal 138 is already represented in Figure 10 as a pressure range that takes the maximum waste container pressure signal 138 into account.

[0071] The maximum waste container pressure signal 138 is typically the highest pressure achievable with the first vent valve 54 and the second vent valve 60 fully closed, without obstructing the ultrasonic surgical handpiece tip 30. In some cases, with the tip fully open and a small pressure difference between the lowest and highest suction conditions, the achievable highest pressure is set higher than the maximum waste container pressure.

[0072] The minimum achievable steady-state suction pressure is the measurement from the second sensor 57, taken from the second portion 40b of the suction passage 40, with the first and second vent valves 54,60 fully open and the surgical handpiece tip 30 attached to the surgical handpiece 28 and console 20. This value is used to set the lowest possible vent-side pressure setpoint. Without it, many of the low-pressure setpoints in suction would be indistinguishable from one another. That is, the pressure setpoint is always below the measured pressure and will never reach the desired setpoint with the first and second vent valves 54,60 fully open.

[0073] Returning to Figure 10, the second PID control loop 128 is used for high-speed control of the suction pressure available at the tip 30 of the ultrasonic surgical handpiece via the second vent valve 60, enabling a constant suction pressure even under conditions where the suction load / occlusion changes rapidly. This is desirable for the surgeon for delicate, precise, and high-speed control of the suction force available at the tip. The time scale of pressure changes at the tip is much faster than the time scale of the waste container and is limited only by the volume of the tube connecting the second sensor 57 to the surgical handpiece tip 30. This second PID control loop 128 operates with similar inputs and in a similar manner to the first PID control loop 126.

[0074] In the second PID control loop 128, the actual pressure measurement is obtained from a second sensor 57 connected to the second portion 40b of the suction passage 40 or communicating with the dirty side passage 460. In this example, the second sensor 57 outputs a voltage signal based on the measured pressure. This voltage signal can be converted to a pressure measurement using a second voltage-to-pressure converter 131. The measured tip pressure signal 133 is coupled with a target tip pressure signal 135 by a second coupler 146. The target tip pressure signal 135 is determined based on parameters stored in a memory device associated with each surgical handpiece tip.

[0075] Additionally or alternatively, the target tip pressure signal 135 may be based on a tip blockage threshold. The tip blockage threshold may be a parameter stored in a memory device associated with each surgical handpiece tip, or in a memory 168 associated with the controller 102. Once the tip blockage threshold is determined, the system 42 enters a blockage detection system using the operation routine 300 to determine whether a blockage has been detected in the ultrasonic surgical handpiece 28. The operation routine 300 is described in detail below.

[0076] The second PID control loop 128 calculates a target tip pressure 135 from the suction setpoint 140, the foot pedal setpoint 142, the minimum handpiece pressure signal 136, and the maximum waste container pressure signal 138. The target tip pressure signal 135 is combined with the measured tip pressure signal 133 to generate a tip pressure error signal 150. It should be understood that the tip pressure error signal 150 is a tip error signal based on the tip pressure signal 133. In this configuration, the target tip pressure signal 135 is combined with the negative value of the measured tip pressure signal 133. The difference between the two signals is the handpiece pressure error signal 150. The tip pressure error signal 150 is supplied to the second PID controller 154. The second PID controller 154 also receives signals indicating the maximum second vent current 160 and the minimum second vent current 162 for the second vent valve 60. The second PID controller 154 outputs a second vent current 166 that opens and closes the second vent valve 60. In this configuration, the second vent current 166 is inverted so that a larger second vent current 166 opens the second vent valve 60 more, and a smaller second vent current 166 closes the second vent valve 60 more.

[0077] The positions of the first and second vent valves 54,60 can be stored in the memory device 168 by the console 20. Alternatively, the positions of the first and second vent valves 54,60 may be based on a comparison, combination, evaluation, or mathematical relationship between the measured waste container pressure signal 132 and the target waste container pressure signal 134, and between the measured tip pressure signal 133 and the target tip pressure signal 135, respectively.

[0078] Figure 11 shows an example of how a target pressure signal can be set and how such a signal can relate to the suction setpoint 140, the minimum handpiece pressure signal 136, and the maximum waste container pressure signal 138. In addition to the minimum handpiece pressure 136 and the maximum waste container pressure 138, there are two other points to consider in Figure 11. There is a low point indicated by LP on the line representing the actual waste container pressure and the target waste container pressure. There is a point LP where the waste container pressure remains consistently higher than the target waste container pressure 134 while being controlled at a very low suction setpoint. This means that the system 42 is fully controlled by the second vent valve 60. In this scenario, the system 42 has lower pressure at the tip 30, providing a sense of a lower suction setpoint, while the suction line between the cassette 34 and the surgical waste container 70 is cleared faster, reducing clogging.

[0079] At the upper limit of the point indicated on the HP on the line representing the actual and target handpiece pressure, the second vent valve 60 closes completely, allowing for a change to a higher pressure. This response is fast because the main air pressure capacity of the surgical waste container 70 has already been sufficiently emptied, and all that remains is in the tube itself of the second portion 40b of the suction passage 40. This allows for a higher setpoint to quickly achieve the desired higher pressure. Under a load of a suction setpoint higher than this point, the pressure of the system 42 quickly matches the upper limit of the control target.

[0080] Finally, as can be seen from the graph in Figure 11 and the schematic diagram in Figure 12, the system 42 may be designed so that higher pressure is maintained in the first portion 40a of the suction passage 40 than in the second portion 40b of the suction passage 40. Additionally or alternatively, higher pressure is maintained in the "clean side" of the system 42 than in the "dirty side," with the surgical waste container 70 providing a functional boundary between the two sides. In other words, higher pressure is maintained from the surgical waste container 70 and filter 72 to the suction pump 74, while lower pressure is maintained in the surgical handpiece tip 30 and the rest of the suction passage 40. The pressure difference is maintained by the controller 102, which controls the first and second vent valves 54, 60. When air enters the second portion 40b of the suction passage 40 through the second vent valve 60, the pressure at the surgical handpiece tip 30 drops rapidly.

[0081] Figure 12 shows a schematic diagram of a suction system using schematic electrical connections to represent air resistance. As shown, there are three components (clean-side tube, filter 72, and surgical waste container / canister tube) between one side of the surgical waste container 70 and the pinch valve 62. On the other hand, there is a dirty-side tube between the pinch valve 62 and the surgical waste container 70. The "dirty side" is provided with two dirty-side tubes and a ball valve 86 / fluid backflow device 462. A second sensor 57 (including differential pressure sensor 50b and gauge pressure sensor 52), a second vent valve 60, and a diffuser are provided in communication with the ball valve 86 / fluid backflow device 462. The "clean side" is provided with a suction pump 74, a first sensor 48 (including differential pressure sensor 50a and gauge pressure sensor 52a), a clean-side tube, a filter 72, and a surgical waste container / canister filter. A muffler filter is provided in communication with the suction pump 74.

[0082] Due to the large capacity of the surgical waste container 70 and the air resistance of the system 42, a higher pressure can be maintained in the first portion 40a of the suction passage 40 for a predetermined time, even when all parts of the suction passage 40 are connected. The pressure difference helps ensure that surgical waste does not enter the first portion 40a of the suction passage 40. This is important because the tubing between the filter 72 and the suction pump 74 is not exchanged between patients.

[0083] III. Clogging Detection During operation of the ultrasonic surgical handpiece 28, a common problem arises from clogging or blockage of the handpiece tip 30. While the tip 30 is clogged, the suction pump 74 continues to operate, and suction pressure builds up inside the ultrasonic surgical handpiece 28. Eventually, as the blockage is cleared, the pressure decreases, causing a large amount of surgical waste to be aspirated too rapidly. This is known as a post-occlusion surge. Referring to Figure 13, the system may implement an operating routine 300 that determines whether or not a blockage has been detected inside the surgical handpiece 28. The operating routine 300 is designed to reduce and / or prevent surges.

[0084] By interfaced with the measurements from the first sensor 48 and the second sensor 57, and the first vent valve 54 and the second vent valve 60, respectively, the operating routine 300 determines whether or not a blockage has been detected in the surgical handpiece 28 through the following steps. In one configuration, the measurements from the first and second sensors 48 and 57 may be the first flow rate and the second flow rate, respectively.

[0085] Other advantages of the system 42 implementing the operating routine 300 include, but are not limited to, maintaining an ideal tissue resection rate, automatically adjusting suction to maintain an ideal flow rate for ultrasonic tissue resection, warning the user of potential blockages, and automatically clearing blockages within the system.

[0086] Referring to Figures 2 and 10 in addition to Figure 13, the operating routine 300 begins in step 301, where a tip-clogging threshold is provided. In one configuration, when the system 42 is turned on and the surgical handpiece tip is attached, the tip-clogging threshold is calculated from the maximum pressure based on the maximum open-loop response under no load. In other configurations, the tip-clogging threshold may be a parameter stored in a memory device associated with each surgical handpiece tip, such as a memory sleeve device located in a sleeve associated with the tip. The tip-clogging threshold can help determine possible clogging.

[0087] In step 302, system 42 enters the blockage control loop. In step 304, actual pressure measurements are obtained from the first sensor 48 and the second sensor 57. In one configuration, the first sensor 48 and the second sensor 57 may be differential pressure sensors 50a and 50b, respectively. In other configurations, the first sensor 48 and the second sensor 57 may be flow sensors.

[0088] Then, in step 306, the measurements from the first and second sensors 48 and 57 can be compared to a first predetermined parameter using either the first or second PID pressure control loops 126 and 128. The first predetermined parameter may be stored in a memory device associated with the tip 30 or in the memory device 168 of the controller 102. If the tip clogging threshold is greater than the first predetermined parameter and the suction set value 140 is greater than a predetermined percentage limit, the operation routine 300 proceeds to step 308. The predetermined percentage limit may be a percentage stored in a memory device associated with the surgical handpiece tip 30 or in the memory device 168 of the controller 102.

[0089] In step 308, the controller 102 indicates that a blockage has been detected in the surgical handpiece 28, and the operation routine 300 proceeds to step 310.

[0090] In step 310, first and second suction pressure measurements 180,182 are obtained from first and second sensors 48,57. More specifically, the differential pressure sensors 50a,50b of the first and second sensors 48,57 output first and second input signals 232,233, respectively, based on the change or decrease in pressure within the first and second portions 40a,40b of the suction passage 40.

[0091] Subsequently, in step 312, the first and second flow rates are estimated based on the pressure measurements from the first and second sensors 48 and 57, respectively. In one configuration, the controller 102 can estimate the first flow rate based on the input signal from the differential pressure sensor 50a. Similarly, the controller 102 can estimate the second flow rate based on the input signal from the differential pressure sensor 50b. Alternatively, in a configuration where the first sensor 48 and the second sensor 57 are flowmeters, the controller 102 can determine the first and second flow rates based on the flow rate measurements from the first and second sensors 48 and 57.

[0092] To calibrate the position of the first vent valve 54 to the first flow rate, the operating routine 300 may repeatedly evaluate the position of the first vent valve 54. In step 314, if the first vent valve 54 is closed, the operating routine 300 proceeds to step 316, where the first flow rate is set to 0. If the first vent valve 54 is open, the operating routine 300 proceeds to step 318.

[0093] In step 318, the second suction pressure 182 is evaluated and the second flow rate is calibrated. If the second suction pressure 182 at the second sensor 57 is less than the second predetermined parameter, the operation routine 300 proceeds to step 320, where the second flow rate is set to 0. The second predetermined parameter may be a parameter stored in either of the memory devices 168, 169 described above. In one configuration, the second predetermined parameter may be a pressure unit representing pounds of force per square inch (PSI). For example, the second predetermined parameter may be 0.005 PSI.

[0094] Once the first and second flow rates are calibrated, in step 322, the controller 102 estimates the tip flow rate based on the second flow rate. The controller 102 then continuously evaluates the tip flow rate over a first predetermined time interval using input from the timer to determine the average tip flow rate. As described above, the measurement from the second sensor 57 better represents the actual measurement at the surgical handpiece tip 30, and therefore the tip flow rate can be estimated from the second flow rate. As shown in Figure 10, the timer is connected to the controller 102. The timer is operable to measure the duration of the tip blockage signal.

[0095] The average tip flow rate can be calculated from a moving average of the tip flow rates. In other words, the controller 102 samples the tip flow rate over a first predetermined time interval and stores a specific number of tip flow rate measurements in a rolling window. Once a specific number of tip flow rates are stored in the rolling window, the most recent sample of tip flow rate replaces the oldest sample before the most recent average is calculated. For example, if the first predetermined time interval is 3 seconds and the specific number is 5, then the moving average is calculated for 5 tip flow rate samples per second, and each tip flow rate is discarded every 3 seconds. It should be understood that the predetermined time interval may be stored in a memory device associated with the tip 30 of the ultrasonic surgical handpiece 28, in memory 168 associated with the controller 102, or in any other memory.

[0096] In step 324, the average tip flow rate is compared to the tip blockage threshold. If the average tip flow rate is less than the tip blockage threshold, the operation routine 300 proceeds to step 328. If the average tip flow rate is greater than the tip blockage threshold, the operation routine 300 proceeds to step 326, where the timer is reset or cleared and the tip blockage signal is reset. In other words, the controller 102 determines that there is no blockage in the surgical handpiece 28, and the operation routine 300 returns to step 302.

[0097] In other configurations, the average tip flow rate may be compared to a third predetermined parameter. The third predetermined parameter may be a parameter stored in one of the memory devices described above. Similar to the comparison with the tip clogging threshold, if the average tip flow rate is greater than the third predetermined parameter, the timer and tip clogging signal are reset or cleared. The operation routine 300 returns to step 302.

[0098] If the average tip flow rate is less than the tip clogging threshold or a third predetermined parameter, the operation routine 300 proceeds to step 328. In steps 328-330, if the timer is not activated, the timer is activated or incremented from the zero time start value.

[0099] Next, using a timer, the operation routine 300 evaluates the average tip flow rate during a second predetermined time interval in step 332. If the average tip flow rate is less than the tip clogging threshold or a third predetermined parameter for a longer period than the second predetermined time interval, the controller 102 outputs a tip clogging signal in step 334.

[0100] If a tip blockage signal is output from the operating routine 300, the controller 102 indicates that a blockage has been detected in the surgical handpiece 28 or in the tip of the surgical handpiece 28. The user and / or controller can then determine the next steps to remove the blockage and maintain an ideal tissue resection rate. In one configuration, if a tip blockage signal is output, the controller 102 may automatically adjust the positions of the first and second vent valves, control the suction level of the suction pump 74, and adjust the suction setpoint or any combination thereof. For example, as shown in Figure 10, the tip blockage signal is one of the inputs to the second PID controller. The controller 102 may control the position of the second vent valve 60 based on the input of the tip blockage signal.

[0101] When a tip blockage signal is output in step 334, the operating routine 300 returns to step 302, and the operating routine 300 can return to the blockage control loop. This allows the system 42 to automatically implement the operating routine 300 and detect any blockages that may occur in the surgical handpiece 28.

[0102] Please understand that the terms "include," "includes," and "including" have the same meaning as the terms "comprise," "comprises," and "comprising."

[0103] For the purposes of this specification, it should be understood that various alternative directions can be assumed unless otherwise expressly specified. It should also be understood that certain devices and processes illustrated in the accompanying drawings and described in the following specification are merely illustrative configurations of the inventive concept as defined herein. Accordingly, certain dimensions and other physical properties relating to the configurations disclosed herein should not be considered as being limited thereto unless expressly provided otherwise in the claims.

[0104] Bullet points (Clauses): 1. A suction system that controls the suction pressure in an ultrasonic surgical handpiece to improve control responsiveness during suction, The ultrasonic surgical handpiece is fluid-connected to a console which includes a controller, a suction pump, a first sensor, a fluid backflow device, a second sensor, a cleanside ventilation mechanism, and a second ventilation mechanism. The controller is configured to control the cleanside ventilation mechanism based on the input signal from the first sensor. The controller is configured to control the second ventilation mechanism based on the input signal from the second sensor. Suction system.

[0105] 2. A suction system that controls the suction pressure in an ultrasonic surgical handpiece to improve control responsiveness during suction, The ultrasonic surgical handpiece is fluid-connected to a console comprising a controller, a suction pump, a first ventilation mechanism, and a second ventilation mechanism, wherein the suction system is configured to be positioned in communication with a surgical waste container. The controller is configured to control the second ventilation mechanism in response to the aspiration of liquid and solid substances that have passed through the surgical handpiece, and the controller is configured to control the first ventilation mechanism to maintain a desired pressure in the surgical waste container. Suction system.

[0106] 3. A suction system for controlling suction pressure in an ultrasonic surgical handpiece, Suction pump and A first joint port, a second joint port, and a third joint port are defined, wherein the first joint port is a joint connecting a first flow path extending from the ultrasonic surgical handpiece, A second flow path is connected to the second joint port and also to the surgical waste container port, A third flow path connected to the third joint port, A fourth channel connected to the second surgical waste container port, A first sensor connected to the fourth flow path and configured to supply a first signal, A second sensor connected to the third flow path and configured to supply a second signal, A controller configured to output a tip blockage signal based on the first signal and the second signal, and to control the suction pump based on the tip blockage signal, A suction system is provided.

[0107] 4. A suction system for controlling suction pressure in an ultrasonic surgical handpiece, A console including a suction pump, A joint is defined which has a first joint port, a second joint port, and a third joint port, wherein the first joint port is connected to a first flow path extending from the ultrasonic surgical handpiece, A second flow path is connected to the second joint port and also to the surgical waste container port, A third flow path connected to the third joint port, A fourth channel connected to the second surgical waste container port, A first sensor connected to the fourth flow path and configured to supply a first signal, A second sensor connected to the third flow path and configured to supply a second signal, A first vent valve connected to the fourth flow path, A second vent valve connected to the third flow path, A controller configured to determine a first flow rate based on the first signal, determine a second flow rate based on the second signal, output a tip blockage signal based on the first and second signals, and control the position of the first vent valve and / or the position of the second vent valve based on the tip blockage signal, A suction system is provided.

[0108] 5. A method for controlling the suction pressure in an ultrasonic surgical handpiece, A step of driving a suction pump to generate suction pressure within the suction system, The steps include determining a first flow rate in a dirty side channel positioned between the ultrasonic surgical handpiece and a fluid backflow device, The steps include determining a second flow rate in a cleanside channel positioned between the suction pump and the surgical waste container, A step of outputting a tip blockage signal based on the average tip flow rate derived from the first flow rate and the second flow rate, The steps include controlling the suction pump based on the tip blockage signal, A method for providing it.

[0109] 6. Define the cassette insertion slot and include a console with two pneumatic console ports within it. A suction source connected to or integrated with the console and communicating with one of the pneumatic console ports, A first pressure sensor integrated into the console and communicating with the other end of the pneumatic console port, A second pressure sensor is integrated into the console and communicates with one of the pneumatic console ports, A cassette is selectively and slidably disposed within the cassette insertion opening, Equipped with, The aforementioned cassette is Within it is a housing that is essentially rigid and defines the chamber, The fluid transfer section of the pump, including the suction side and discharge side of the pump, A plurality of fluid passages, at least partially located within the chamber, Equipped with, The aforementioned plurality of fluid passages are A first fluid passage including a first end connected to the suction side and a second end connected to the supply fluid container, A second fluid passage including a first end connected to the discharge side and a second end connected to the handpiece, A third fluid passage including a first end connected to the handpiece and a second end connected to the waste container, The housing includes a first end connected to a first console connector and a second end connected to the waste container, the first console connector having a fourth fluid passage having a first pneumatic connector port that is pneumatically connected to one of the pneumatic console ports when the cassette is inserted into the cassette insertion opening, A fifth fluid passage having a first end connected to the third fluid passage and a second end connected to the second console connector of the housing, wherein the second console connector has a second pneumatic connector port that is pneumatically connected to the other side of the pneumatic console port when the cassette is inserted into the cassette insertion opening, Equipped with, Fluid management system.

[0110] 7. A method using a surgical irrigation cassette, The step of providing a surgical irrigation cassette having a substantially rigid housing defining a chamber, a compressible peristaltic pump tube located outside the housing, and a plurality of fluid passages located at least partially within the chamber, wherein the plurality of fluid passages include a first fluid passage including a first end connected to a first end of the pump tube and a second end connected to a supply fluid container, a second fluid passage including a first end connected to a second end of the pump tube and a second end connected to a handpiece, a third fluid passage including a first end connected to the handpiece and a second end connected to a waste container, a fourth fluid passage including a first end connected to a first console connector fixed to the housing and a second end connected to the waste container, and a fifth fluid passage having a first end connected to the third fluid passage and a second end connected to a second console connector fixed to the housing, The steps include inserting the cassette into a control console that includes or is connected to a suction source, The steps include connecting the second end of the first fluid passage to the supply fluid container, The steps include connecting the second end of the second fluid passage to the handpiece, The steps include connecting the first end of the third fluid passage to the handpiece, The steps include connecting the second end of the third fluid passage to the waste container, The steps include connecting the second end of the fourth fluid passage to the waste container, A method for providing it.

[0111] The above description has illustrated several embodiments. However, the embodiments discussed herein are not intended to be exhaustive or to limit this disclosure to any particular form. The terms used are intended to be descriptive and not limiting. With regard to the above teachings, various modifications and variations are possible, and this disclosure can be implemented in ways other than those specifically described.

Claims

1. A suction system that controls the suction pressure in an ultrasonic surgical handpiece to improve control responsiveness during suction, Suction pump and A suction passage extending at least partially between a surgical handpiece connector and the suction pump, further including a joint that divides the suction passage into at least two flow paths, A first sensor is connected to a first portion of the suction passage, which is positioned between the surgical waste container connector and the suction pump, and is configured to monitor the waste container pressure and supply a waste container pressure signal. A first vent valve connected to the first portion of the suction passage, A second vent valve connected to the end of the second portion of the suction passage that begins at the joint, A second sensor connected to the second portion of the suction passage and configured to monitor the suction pressure associated with the tip of the ultrasonic surgical handpiece and to supply a tip pressure signal, A controller configured to control the first vent valve based on the waste container pressure signal and the second vent valve based on the tip pressure signal, A pinch valve that fits into a third portion of the suction passage, wherein the third portion of the suction passage extends from the joint to the surgical waste container connector, and the pinch valve is configured such that the suction pressure does not reach the tip of the ultrasonic surgical handpiece when the pinch valve is in operation. A three-way valve connected to the pinch valve, the three-way valve configured to connect the pinch valve to the atmosphere and / or the first portion of the suction passage, A suction system is provided.

2. The joint comprises a joint valve that is operable to divide the suction passage, the joint valve having a first joint port, a second joint port, and a third joint port, the second portion of the suction passage being connected to the third joint port. The suction system according to claim 1.

3. The joint valve is a ball valve that prevents surgical waste from entering the second portion of the suction passage. The suction system according to claim 2.

4. The third portion of the suction passage is connected to the second joint port and to the surgical waste container connector. The suction system according to claim 2.

5. The first portion of the suction passage includes a clean side flow path. The second portion of the suction passage includes a dirty side passage, A suction system according to any one of claims 1 to 4.

6. The first portion of the suction passage has a larger volume than the second portion of the suction passage. A suction system according to any one of claims 1 to 5.

7. The controller is further configured to control the first vent valve to maintain a desired pressure in the surgical waste container. A suction system according to any one of claims 1 to 6.

8. The controller further comprises a first PID control loop for controlling the first vent valve and a second PID control loop for controlling the second vent valve. A suction system according to any one of claims 1 to 7.

9. The first PID control loop is configured to determine a waste container error signal based on a waste container pressure signal supplied by the first sensor connected to the first portion of the suction passage, and a target waste container pressure. The second PID control loop is configured to determine a tip error signal based on the tip pressure signal supplied by the second sensor connected to the second portion of the suction passage, and the target tip pressure. The suction system according to claim 8.

10. A suction system that controls the suction pressure in an ultrasonic surgical handpiece to improve control responsiveness during suction, A console with a suction pump, Ultrasonic surgical handpiece, Surgical waste container, A clean-side channel is positioned between the suction pump and the surgical waste container, A dirty side channel is provided between the ultrasonic surgical handpiece and the surgical waste container. A fluid backflow device communicating with the dirty side channel, A cleanside ventilation mechanism that communicates with the cleanside flow path, A second ventilation mechanism communicating with the aforementioned fluid backflow device, A pinch valve that is aligned with the dirty side flow path and is configured such that the suction pressure does not reach the tip of the ultrasonic surgical handpiece when the pinch valve is operating, A three-way valve configured to connect the pinch valve to the atmosphere and / or the clean side flow path, A suction system is provided.

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