Abstract:
A system and method for powered surgical handpiece capable of powering various micro-cutting instruments is described. The system is comprised of a controller adapted for controlling/interfacing with a powered surgical handpiece based upon user-defined procedural information. A data entry device is used for entering the user-defined procedural information used by the controller for configuring and operating the motor control system.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims the benefit of, and incorporates herein by reference the entirety of, U.S. Provisional Application Ser. No. 60/235,217, filed on Sep. 24, 2000. 

   BACKGROUND OF THE INVENTION 
   The present invention generally relates to powered handpieces for driving surgical cutting instruments. More particularly, it relates to a control system for interfacing with a powered surgical handpiece and controlling operation thereof. 
   Powered surgical handpieces are commonly used in many medical specialties to drive surgical blades or cutting instruments for performing various diverse cutting functions including resection, comminution, dissection, debridement, shaving, drilling, pulverizing, and shaping of anatomical tissue. In the areas of ENT/head/neck surgery, the handpieces are typically configured for selective coupling to, and driving of, a variety of different micro-cutting surgical instrument design to perform a specific procedure. During use, based upon the specific surgical procedure, the surgeon selects the appropriate micro-cutting tool and mounts it to the powered handpiece. The powered handpiece is then operated to move one or more components of the micro-cutting tool (e.g., rotation, oscillation) required to perform the surgical operation. As a point of reference, the rotational requirements typically required by a powered surgical handpiece for ENT/head/neck procedures range from about 500 rpm for a laryngeal skimming operations to in excess of 60,000 rpm for high-speed drill operations. The common speed range of the powered surgical handpiece is from about 300 rpm to about 80,000 rpm. 
   In addition to motor improvements, such as use of brushless DC motors, overall systems have been developed for use with the powered surgical handpiece and related surgical micro-cutting instruments. A typical system, in addition to a powered handpiece and one or more micro-cutting instruments, includes a control console and a cable that connects the handpiece to the console. The control console is configured to activate and/or control energization of the motor otherwise associated with the powered surgical handpiece. For example, a hand or foot switch can be provided as part of the system. Depending upon the surgeon&#39;s manipulation of the foot or hand switch, a corresponding signal is delivered to the control console that, in turn, energizes the handpiece to a corresponding speed. 
   The improved capabilities of powered surgical handpieces, as well as the vast number of available surgical micro-cutting instruments now available, have undoubtedly greatly increased the number of ENT/head/neck procedures that a surgeon can perform utilizing a single surgical system. However, with the substantial expansion in available procedures, the opportunity for improper device selection and/or operation has arisen. That is to say, because a surgeon can now use a single handpiece with a variety of different micro-cutting instruments to perform a number of different procedures, it is possible that surgical personnel may inadvertently operate the handpiece at settings that are less than optimal for a particular surgical procedure. For example, a surgeon performing a laryngeal tricut procedure with a micro-resecting instrument may accidentally attempt to operate the powered handpiece at speeds well in excess of the recommended 1,200 rpm limit because the surgeon has failed to adjust the control panel settings from a previous, different procedure; surgical personnel have been unable to recall the preferred settings, etc. Other operational settings, such as rotational mode (e.g., forward, reverse, oscillate), irrigation settings, etc., must also be determined and properly implemented by the surgical personnel, again increasing the opportunity for error. 
   Powered surgical handpieces, and in particular, powered handpieces configured to selectively receive a multitude of different micro-cutting instruments useful for ENT/head/neck surgeries, are highly desirable. However, the enhancement of available features may give rise to unintentional misoperation. Therefore, a need exists for an interactive powered surgical handpiece control system that controls surgical handpiece operation while providing information, assistance and/or control to the surgeon specific to a particular surgical operation. 
   SUMMARY OF THE INVENTION 
   One aspect of the present invention provides a motor control system for a powered surgical handpiece capable of powering various micro-cutting instruments. A controller is adapted for controlling/interfacing with a powered surgical handpiece based upon user-defined procedural information. A data entry device enables allows entry of user-defined procedural information used by the controller for configuring and operating the motor control system. 
   Another aspect of the present invention provides a surgical micro-cutting system. A surgical micro-cutting is used for performing diverse cutting functions. A powered surgical handpiece is configured to receive and drive the surgical micro-cutting instrument. A controller that operates the surgical micro-cutting system according to user-defined procedural information. 
   Another aspect of the present invention provides a method of controlling a powered surgical handpiece. The system includes a controller, a control console and a powered surgical handpiece capable of powering a micro-cutting instrument. The system detects whether the powered surgical handpiece is connected to the controller. The controller is operated to determine whether the micro-cutting instrument has been coupled to the powered surgical handpiece. Information and operational characteristics associated with user-defined procedural information entered by a user via the control console are generated and preferred operational settings are displayed based upon the generated information and operational characteristics. The system powers the powered surgical handpiece according to the operational characteristics associated with the user-defined procedural information. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a block diagram of a powered surgical handpiece control system in accordance with the present invention; 
       FIG. 2  is a flow diagram illustrating generally use of the control system of  FIG. 1 ; 
       FIG. 3  is a flow diagram illustrating a warning operation performed by one preferred embodiment of the control system of  FIG. 1 ; 
       FIG. 4  is a flow diagram illustrating one specific application of the control system of  FIG. 1 ; 
       FIG. 5  is a flow diagram illustrating a speed control feature associated with one preferred embodiment of the control system of  FIG. 1 ; and 
       FIG. 6  is flow diagram illustrating an application of the control system of  FIG. 1 . 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   One preferred embodiment of a powered surgical handpiece control system  10  is illustrated in block form in  FIG. 1 . The control system  10  includes a controller  12 , a powered surgical handpiece  14 , a data entry device  16 , a display screen  18 , and a speed controller  20 . The various components of the control system  10  are described in greater detail below. In general terms, however, the handpiece  14 , the data entry device  16 , the display screen  18 , and the speed controller  20  are electrically connected to the controller  12 . During use, the controller  12  detects the presence of the powered handpiece  14 , and receives procedural information from surgical personnel (not shown) via the data entry device  16 . Based upon this information, the controller  12  displays operational information to the surgical personnel at the display screen  18 . Depending upon the particular procedure to be performed, the controller  12  may request and receive additional procedural information from the surgical personnel via the data entry device  16  and/or display additional operational information at the display screen  18 . Once the controller  12  has determined appropriate system configuration, the controller  12  energizes the handpiece  14  to a certain level that can be a default value, selected by the surgical personnel at the data entry device  16 , dictated by operation of the speed controller  20 , etc. 
   In a preferred embodiment, the controller  12 , the data entry device  16 , and the display screen  18  are provided in the form of a singular control console. In a preferred embodiment, the controller  12  is a microprocessor based computer including associated memory and associated input/output circuitry. Alternatively, a programmable logic controller (PLC) or other controller or equivalent circuitry can be employed. 
   The data entry device  16 , which serves as a user interface, can assume a wide variety of configurations, and is preferably a membrane-type touch pad known in the art that is positioned in close proximity to, or integrally formed with, the display screen  18 . Similarly, the display screen  18  can assume a wide variety of forms such as a cathode ray tube or a liquid crystal display. Regardless, the display screen  18  is configured to provide surgical personnel with information relating to operation of the system  10 . 
   The powered surgical handpiece  14  is preferably of a type known in the art and is configured to selectively receive and drive a surgical micro-cutting instrument  22 . Acceptable powered surgical handpieces are available, for example, from Medtronic-Xomed of Jacksonville, Fla., and include a motor  24  and housing  26 . Examples of available powered surgical handpieces are described in U.S. Pat. Nos. 5,910,152 and 5,957,881 the teachings of which are incorporated herein by reference, it being understood that those are but a few examples of acceptable powered surgical handpieces. 
   The surgical micro-cutting instrument  22  can assume a wide variety of forms as known in the art. For example, the micro-cutting instrument  22  can be a micro-resecting instrument, a micro-debriding instrument, a micro-shaving instrument, a micro-drilling instrument, a micro-abrasion instrument, etc. Regardless, the micro-cutting instrument  22  is configured for selectively coupling to, and driving by, the powered surgical handpiece  14 . 
   As is known in the art, many ENT/head/neck micro-cutting procedures require a continuous supply of an irrigation fluid to the target site. For example, both micro-drilling and micro-shaving procedures require fluid irrigation. To this end, the system  10  preferably includes a separate irrigation fluid source  30  that is connected to the controller  12 . With this configuration, the controller  12  controls activation of and/or the flow rate supplied to the target site. For example, in one preferred embodiment, the control system  10  includes, or is connected to, a pump  32  otherwise connected to the irrigation supply source  30 . Upon activation by the controller  12 , the pump  32  directs irrigation fluid to tubing  34  otherwise associated with the housing  26  of the handpiece  14 . As is known in the art, the tubing  34  is preferably fluidly connected to a corresponding portion of the micro-cutting instrument  22  that otherwise directs the irrigation fluid to the target site. One example of an acceptable configuration is provided in U.S. Pat. No. 5,910,152. Alternatively, or in addition, the fluid irrigation supply source  30  can be directly connected to, or associated with, the handpiece  14 , so that surgical personnel can directly control a supply of fluid. 
   Recent enhancements to powered handpiece designs have envisioned use of a liquid for cooling the powered handpiece  14  during use. In this regard, and in one preferred embodiment, the control system  10  further includes a cooling liquid supply source  40 . As with the fluid irrigation supply source  30 , described above, the cooling liquid supply source  40  can be directly connected to the handpiece  14  (e.g., the housing  26 ) for cooling thereof, or can be directed through, or controlled by, the controller  12 . 
   Use of the control system  10  for controlling the surgical handpiece  14  is illustrated generally by the flow diagram of  FIG. 2 . With additional reference to  FIG. 1 , one preferred method of using the system  10  of the present invention begins at step  50  at which the controller  12  detects the presence of the surgical handpiece  14 . For example, the powered surgical handpiece  14  can include a cord assembly  24  (not shown) terminating in a connector plug (not shown) that is otherwise connectable to a receiving port or socket (not shown) electrically connected to the controller  12 . An example of an acceptable connection is provided in U.S. Pat. No. 5,903,117, the teachings of which are incorporated herein by reference. Alternative connection systems known in the art are equally acceptable, so long as the controller  12  is able to determine whether the surgical personnel have initiated a surgical procedure by selecting and connecting the handpiece  14 . If, at step  50 , the controller  12  does not defect the handpiece  14 , operations do not continue. 
   Assuming the handpiece is properly connected, at step  52 , the controller  12  determines whether the micro-cutting instrument  22  has been coupled to the handpiece  14 , and the type of instrument. In this regard, the powered handpiece  14  can be configured to provide the controller  12  with a signal indicative of mounting of the micro-cutting instrument  22 . Alternatively, surgical personnel may inform the controller  12  of the presence of the micro-cutting instrument  22  via the data entry device  16 . In this regard, the controller  12  can receive information, either directly from the surgical handpiece  14  or from surgical personnel via the data entry device  16 , indicative of the exact form the micro-cutting instrument  22 . Alternatively, however, the system  10  does not require confirmation of the specific form of the micro-cutting instrument  22  to continue. 
   At step  54 , the controller  12  generates information and operational characteristics associated with the particular surgical procedure to be performed. As described below, in a preferred embodiment, the controller  12  requests, via the display screen  18 , surgical personnel to enter the particular procedure to be performed. For example, the surgical personnel can select, via the data entry device  16 , a general anatomical location for the operation from a list generated by the controller  12  at the display screen  18 . Additionally, or alternatively, the surgical personal can select a specific surgical procedures and corresponding anatomical location from a list generated by the controller  12  at the display screen  18 . Even further, the controller  12  can have previously stored surgical procedure information that corresponds with the particular micro-cutting instrument  22  and/or the particular handpiece  14  otherwise connected to the controller  12 . With this configuration, the controller  12  selects appropriate procedural information from this database based upon the detected or sensed handpiece  14 /micro-cutting instrument  22  information. 
   At step  56 , the controller  12  causes the display screen  18  to display preferred operational settings based upon the generated surgical procedure information. For example, and as described below, the controller  12  signals the display screen  18  to display the preferred handpiece operational speed, the rotational mode, the fluid irrigation flow rate, and information identifying the surgical procedure for which the preferred settings relate. Upon reviewing the displayed information, the surgical personnel can confirm that the desired surgical procedure has been selected and can confirm the preferred operational settings. As a result, the surgical personnel are no longer required to separately investigate suggested settings, and, in one preferred embodiment, can rely upon the displayed values as default settings for the system  10 . 
   At step  58 , the controller  12  allows for operation of the powered surgical handpiece  14 . For example, the surgeon can deploy the micro-cutting instrument  22  to the target site and initiate activation of the powered handpiece  14 , for example via the speed controller  20 . In response, and assuming that all previous steps have been properly performed, the controller  12  energizes the powered handpiece  14  such that the surgeon can complete the desired surgical procedure. In a preferred embodiment, the controller further activates and controls fluid flow from the irrigation fluid supply source  30  and the cooling fluid supply source  40  in accordance with desired operational parameters. As a point of reference, one example of controlled powering of a surgical handpiece is described in U.S. Pat. No. 5,903,117, the teachings of which are incorporated herein by reference. It should be understood, however, that a wide variety of other techniques for signaling, operating, and controlling a powered surgical handpiece, fluid sources, etc. via a controller are known in the art and are equally acceptable. 
   In a preferred embodiment, the controller  12  allows the surgeon (not shown) to control the speed of the powered surgical handpiece  14  via the speed controller  20 . As previously described, the speed controller  20  is preferably a foot switch that is highly convenient for a surgeon&#39;s use. In a preferred embodiment, the controller  12  is configured to prevent operation of the handpiece  14  at speeds that would be inappropriate for the procedure being performed. For example, the controller can be provided with a lower limit and an upper limit speed value database specific to particular surgical procedures. When the surgeon attempts to operate the handpiece  14 , for example, via the speed controller  20 , above or below the limit values, the control system  12  prevents the handpiece  14  from being so-operated, for example by not signaling or otherwise energizing the handpiece  14  above or below the limiting values. 
   Alternatively, the control system  10  can be configured to allow operation of the powered handpiece  14  above or below the pre-set limiting values, but provides the surgical personnel with a warning. For example, as shown by the flow diagram of  FIG. 3 , at step  70 , the controller  12  determines whether the particular configuration of the handpiece  14  and the micro-cutting instrument  22  has a prescribed or preferred speed limit or range. As shown in  FIG. 3 , for example, the controller  12  includes a speed limit database containing limiting values for a micro-resector cutting instrument and a high-speed micro-drilling instrument. At step  72 , the controller  12  determines that a micro-resecting instrument is being utilized as the micro-cutting instrument  22  and determines whether the surgeon is attempting to operate the powered handpiece  14  at speeds in excess of a pre-set value, for example, 6,000 rpm. If, at step  72 , it is determined that the surgeon is not attempting to operate the handpiece  14  in excess of the preset value (or “no” at step  72 ), the method returns to step  70 , and no warning is displayed. 
   Alternatively, if at step  72 , the controller  12  determines that the surgeon is attempting to operate the powered handpiece  14  at speeds in excess of the preset limit, the method proceeds to step  74 . A similar methodology is followed at step  76  relating to use of a high-speed micro-drill having a different present limit, for example 52,000 rpm. 
   Regardless, if the controller  12  determines, either at step  72  or step  76 , that the surgeon is attempting to operate the handpiece  14  at a speed outside of the predetermined range, at step  74  the controller  12  causes the display screen  18  to display a warning to the surgical personnel, prevents the powered handpiece  14  from being operated at the requested speed (that is otherwise outside of the predetermined range) and requests information from the surgical personnel. For example, the warning associated with step  74  can indicate to the surgical personnel that a different micro-cutting instrument is better suited for the desired speed. Alternatively, other warnings can be provided. 
   If, at step  74 , the surgical personnel chooses to not exceed the preselected speed range (“exit” at step  74 ), operation of the handpiece  14 , via the controller  12  continues but at a level within the predetermined range, or the procedure can be stopped entirely so that a more appropriate micro-cutting instrument can be used. Alternatively, if the surgical personnel determines that the particular micro-cutting instrument  22  and the desired, non-conforming speed is appropriate (“continue” at step  74 ), the controller  12  proceeds to step  78  at which the controller  12  energizes the surgical handpiece  14  to the requested level. 
   One specific method of using the system  10  of the present invention is shown by the flow diagram of  FIG. 4 . Beginning at step  90 , the controller  12  causes the display screen to display default information (for example, as described at step  54  in  FIG. 2 ). At step  92 , the controller  12  causes the display screen  18  to request information from the surgical personnel as to the specific form of the micro-cutting instrument  22 . Alternatively, and as previously described, the powered handpiece  14  can be configured to directly signal this information to the controller  12 . Once the type of cutting instrument is determined, the controller  12  determines whether its associated memory includes database information related to the micro-cutting instrument  22 . If, at step  92 , the controller  12  does not recognize the cutting instrument  22  (“no” at step  92 ), the control system  10  proceeds to step  94 , and is unable to provide options to the surgical personnel. Conversely, where the controller  12  does recognize the particular cutting instrument  22 , the control system  10  proceeds to step  96 . By way of reference, the example provided in  FIG. 4  relates to a micro-resector instrument. 
   At step  96 , the controller  12  causes the display screen  18  to display a listing of anatomical regions or procedures for which the selected cutting instrument  22  is particularly adapted. For example, with respect to the micro-resector example of  FIG. 4 , the controller  12  will the cause the display screen  18  to display a listing of four anatomical regions including “sinus,” “plastics” (or plastic surgery), “laryngeal,” and “adenoid”. In response, the surgical personnel select one of the listed procedures or anatomical regions via the data entry device  16 . 
   Depending upon the selection made at step  96 , the method proceeds to one of steps  98  (corresponding to “laryngeal” selection), step  100  (corresponding with “sinus” selection), step  102  (corresponding with “plastics” selection), or step  104  (corresponding with “adenoid” selection). 
   Assuming, for example, that laryngeal is selected, and thus that the method has proceeded to step  98 , the controller  12  causes the display screen  18  to display additional procedural requests. For example, a listing of “tricut” and “skimmer” can be displayed. In response, the surgical personnel must select, via the data entry device  16 , one of the displayed procedures. 
   Assuming, for example, that the surgical personnel selects “tricut” at step  98 , the method proceeds to step  106  at which the controller  12  causes the display screen  18  to display preferred operational parameters associated with the selected procedure. For example, and as shown in the  FIG. 5 , at step  106  the display screen  18  displays a preferred rotational speed (i.e., 1,200 rpm), the selected surgical procedure (i.e., laryngeal tricut), the operational mode (i.e., oscillate), and the irrigation settings (i.e., 40%). Based upon this display, then, the surgical personnel can easily and clearly identify the preferred operational parameters, and can confirm that the information corresponds with the desired procedure. Similar displays are provided for other specifically selected procedures (i.e., indicated general at steps  104  and 108–120). Obviously, the displays illustrated in  FIG. 5  are but a few examples of acceptable formatting and information. 
   An additional operational feature or method associated with the control system  10  of the present invention is provided in  FIG. 5 , whereby the controller  12  confirms preferred operation of the speed controller  20  in either normal, such as “Start/Stop,” or variable mode. 
   In one alternative embodiment, the control system  10  is configured for use with an image guidance system. Image guidance systems are well known in the art, and rely upon stereotactic techniques to assist surgeons in performing operations in or near the head. One example of an acceptable image guidance system is available under the trade name LandmarX from Medtronic-Xomed of Jacksonville, Fla. Regardless of the exact configuration, the image guidance system includes a high-definition screen that displays the patient&#39;s internal anatomy along with a relative position of the particular instrument being employed as part of the surgical procedure. Due to the highly delicate nature of these procedures, the surgeon is required to constantly view the image guidance system display screen. With this in mind, and in the alternative embodiment, the control system  10  is configured such that the controller  12  is directly connected to the image guidance system display screen. Any display generated by the controller  12  relating to operational parameters of the surgical handpiece  14  are offset from or otherwise positioned so as to not interfere with viewing of the image guidance system display. However, by providing the operational parameters display as part of, or immediately adjacent to, the image guidance system display, the surgeon can check the operating conditions for the handpiece continuously as the device is operating without diverting his or her attention away from the screen otherwise showing the position of the tool relative to the patient&#39;s anatomy. 
   The powered surgical handpiece control system and related method of the present invention provides a marked improvement over previous designs. In particular, regardless of the exact surgical procedure and related micro-cutting instrument, the surgical personnel are immediately provided with preferred operational parameters. The control system preferably prevents the surgeon from inadvertently deviating from the generated operational parameters, and provides a simple user interface specific to ENT/head/neck procedures.