Patent Publication Number: US-2023149213-A1

Title: On-the-fly tuning for piezoelectric ultrasonic handpieces

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to systems and probes that utilize piezoelectric vibration, and particularly to phacoemulsification systems and probes. 
     BACKGROUND OF THE INVENTION 
     A cataract is a clouding and hardening of the eye&#39;s natural lens, a structure which is positioned behind the cornea, iris and pupil. The lens is mostly made up of water and protein and as people age these proteins change and may begin to clump together obscuring portions of the lens. To correct this, a physician may recommend phacoemulsification cataract surgery. In the procedure, the surgeon makes a small incision in the sclera or cornea of the eye. Then a portion of the anterior surface of the lens capsule is removed to gain access to the cataract. The surgeon then uses a phacoemulsification probe, which has an ultrasonic handpiece with a needle. The tip of the needle vibrates at ultrasonic frequency to sculpt and emulsify the cataract while a pump aspirates particles and fluid from the eye through the tip. Aspirated fluids are replaced with irrigation of a balanced salt solution to maintain the anterior chamber of the eye. After removing the cataract with phacoemulsification, the softer outer lens cortex is removed with suction. An intraocular lens (IOL) is then introduced into the empty lens capsule restoring the patient&#39;s vision. 
     Various techniques to vibrate a transducer at a resonant frequency of the transducer were proposed in the patent literature. For example, U.S. Pat. No. 4,808,948 describes an apparatus for periodically sweeping a voltage-controlled oscillator over a range of frequencies which includes a resonant frequency of a transducer being supplied with power by the voltage-controlled oscillator through a power amplifier. The apparatus includes a digital phase detector having a voltage input coupled to the output of the power amplifier and a second voltage input coupled to a current sensor indicative of the phase of the current flowing through the supply circuit of the transducer to provide at the output of the phase detector a voltage signal indicative of phase difference between the voltage and the current in the transducer. The output of the phase detector is coupled to a processor and to the input of a summing circuit. The output of the processor is also coupled to the summing circuit to provide an offset voltage which adjusts the voltage-controlled oscillator to the resonant frequency of the transducer. 
     As another example, U.S. Pat. No. 5,959,390 describes a system and method for tuning and controlling ultrasonic handpieces by incorporating a broad-spectrum signal as at least a component of the signal used to drive the handpiece. The response of the handpiece to this broad-spectrum signal is measured and the frequency or amplitude or both of the drive signal are adjusted in order to maintain the desired level of handpiece performance. The operation of the systems and the performance of the methods described enables the handpiece to be operated in a most effective manner over a more widely varying range of mechanical load and thermal conditions than was possible through the use of prior control systems and methods. 
     U.S. Pat. No. 6,626,926 describes how the ability of an ultrasonic system to sweep and lock onto a resonance frequency of a blade subjected to a heavy load at startup is improved by applying a high drive voltage or a high drive current while systematically increasing the level of the applied signal. Increasing the drive signal to the hand piece results in an improved and more pronounced “impedance spectrum.” That is, under load, the increased drive signal causes the maximum phase margin to become higher and the minimum/maximum impedance magnitude to become more pronounced. Increasing the excitation drive signal to the hand piece/blade at startup significantly alleviates the limiting factors associated with ultrasonic generators, which results in an increase of the maximum load capability at startup. 
     SUMMARY OF THE INVENTION 
     An embodiment of the present invention that is described hereinafter provides a method for tuning a phacoemulsification probe during a procedure for treating an eye. The method includes vibrating a piezoelectric actuator of the phacoemulsification probe, by applying to the piezoelectric actuator a tuning signal that (i) covers an operational bandwidth of the phacoemulsification probe and (ii) has an initial power level that is lower than a normal power level set for treating the eye. The tuning signal is measured during an initial signal tuning session. An operating frequency for the phacoemulsification probe is derived from the measured tuning signal. A driving signal, having the normal power level and the derived operating frequency, is applied to the piezoelectric actuator. 
     In some embodiments, applying the tuning signal, deriving the operating frequency, and applying the driving signal having the normal power level, are performed uninterruptedly during a treatment session performed by a user. 
     In some embodiments, applying the tuning signal includes frequency-sweeping a signal across the operational bandwidth. 
     In an embodiment, deriving the operating frequency includes identifying a time of occurrence of a peak in the measured tuning signal, and determining the frequency of the tuning signal at the time of occurrence of the peak. 
     In another embodiment, applying the tuning signal includes applying a signal having an instantaneous bandwidth that covers the operational bandwidth. 
     In some embodiments, deriving the operating frequency includes setting the operating frequency to a resonant frequency of the piezoelectric actuator. 
     In some embodiments, deriving the operating frequency includes setting the operating frequency to a frequency at which a voltage of the tuning signal has a predefined phase offset relative to a current of the tuning signal. 
     In an embodiment, applying the driving signal includes running a closed control loop that retains the normal power level. 
     In some embodiments, applying the driving signal includes running a closed control loop that adapts the operating frequency. 
     There is additionally provided, in accordance with an embodiment of the present invention, a system for tuning a phacoemulsification probe during a procedure for treating an eye. The system includes a piezoelectric actuator of the phacoemulsification probe and a processor. The piezoelectric actuator is configured to be vibrated by applying to the piezoelectric actuator a tuning signal that (i) covers an operational bandwidth of the phacoemulsification probe and (ii) has an initial power level that is lower than a normal power level set for treating the eye. The processor is configured to (a) measure the tuning signal during an initial signal tuning session, (b) derive, from the measured tuning signal, an operating frequency for the phacoemulsification probe, and (c) apply to the piezoelectric actuator a driving signal having the normal power level and the derived operating frequency. 
     The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken together with the drawings in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a schematic, pictorial view, along with a side view, of a phacoemulsification system, in accordance with an embodiment of the present invention; 
         FIG.  2    is a block diagram schematically describing a multi-channel piezoelectric drive system for the phacoemulsification system of  FIG.  1   , in accordance with an embodiment of the present invention; 
         FIG.  3    has graphs of driving frequency and phacoemulsification handpiece power as a function of time, schematically describing an on-the-fly tuning of a resonant mode of probe of  FIG.  1   , in accordance with an embodiment of the present invention; and 
         FIG.  4    is a flow chart schematically describing a method for on-the-fly tuning a resonant mode of the phacoemulsification probe of  FIG.  1   , in accordance with embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Overview 
     A phacoemulsification system typically drives a piezoelectric actuator included in a phacoemulsification probe/handpiece to vibrate a needle of a phacoemulsification probe during a cataract procedure. The piezoelectric actuator of the phacoemulsification probe may be designed to vibrate, in resonance, in a single mode or in multiple modes simultaneously, where each mode has a given “natural” resonant frequency. For example, a multi-resonance mode might yield a complex vibration profile that combines longitudinal, transverse, and torsion vibrations, each with its own resonant frequency. Such a mode may have a complex customizable vibration profile that may allow a physician to better perform phacoemulsification. 
     Prior to a cataract procedure a phacoemulsification handpiece needs to be tuned. The tuning depends on the type of handpiece, and typically comprises either (i) finding a resonant frequency f 0  of a given mode of the piezoelectric actuator of the handpiece, or (ii) finding the frequency where there is a preset phase difference Δϕ (for example −65°) between the voltage and current being applied at the given mode to the piezoelectric actuator. The tuning typically needs to be repeated prior to every procedure, since there are a large number of varying parameters that affect the frequency, e.g., how tightly the phacoemulsification tip is screwed to the handpiece, which tip is used, and the temperatures of elements of the handpiece. 
     The tuning gives an initial frequency at which the handpiece is operated. However, since the resonant frequency changes with power, both the power and the frequency during a procedure are monitored and varied separately. A conventional tuning process may take about 30 seconds, which is a considerable amount of time for a phacoemulsification procedure that typically takes on the order of five minutes. 
     Embodiments of the present invention that are described herein eliminate a separate tuning session by providing an “on-the-fly tuning” technique. In place of a dedicated tuning session, the system is configured so that, on the first activation of the handpiece in a procedure, a very brief, i.e., 50 ms-100 ms, frequency sweep at very low power (e.g., few orders of magnitude lower than a normal power level set for treating the eye) is performed. Performing the frequency sweep typically involves applying to the piezoelectric actuator a tuning signal that (i) covers an operational bandwidth of the phacoemulsification probe and (ii) has an initial power level that is lower than a normal power level set (e.g., lower than the power range provided by the system that a user can select from) for treating the eye. This short frequency sweep is sufficient for a processor driving the handpiece to determine a required initial resonant frequency f 0i  by measuring the tuning signal (typically measuring a peak in the electrical current or voltage of the tuning signal). f 0i  is the frequency where an “objective” metric (e.g., minimum measured admittance) is achieved. In a typical case, f 0i  is the frequency where the real impedance is smallest (admittance is largest), or where the real power highest, assuming voltage amplitude is fixed during the sweep. The duration of such a tuning process is short enough so that it is unnoticeable to the surgeon activating the handpiece. 
     An alternative to frequency-sweeping is for the processor to apply another type of initial waveform to the piezoelectric actuator over the given frequency range as driving signals, which determines the resonant frequency. For example, the processor may apply wide-bandwidth waveforms having a bandwidth of at least the given frequency range. 
     From the sweep (or from wide-bandwidth signal), the processor determines an initial resonant frequency, f 0i , corresponding, for example, to a measured peak in the initial power or peak in real admittance (identified by the processor during the sweep). This frequency is then applied with the “full” (e.g., the aforementioned normal) power that the surgeon expects to use. As a result, there is typically a very slight decrease in the frequency, and a small increase in the power, until resonance at the desired power is achieved. In particular, there&#39;s typically a difference between f 0i  found during the sweep and the optimal frequency for higher power levels (and loading conditions, etc.). It may thus take some time duration, for example, one between several milliseconds and several tens of milliseconds, to find the optimal frequency on the first drastic change in requested power. The processor uses a feedback loop to ensure that the power is kept approximately constant at a nominal value. At the power level requested by the user (the surgeon), the control loop may perform larger adjustments since power is very sensitive to changes in frequency when approaching resonance. 
     In an embodiment, separate processors and feedback loops are used to ensure that the frequency is at resonance and the power is nominal and stable. The frequency is optimal for a given “objective” of the disclosed algorithm, e.g., frequency of highest real admittance. Considering that exact peak resonance frequency may not be always physically achievable, the controller still tracks the optimal frequency (e.g., with some detuning effectively occurring). 
     In an embodiment, one or more processor-controlled drive modules are used to independently drive each of the one or more resonant-frequency modes of vibration. A processing circuitry controls each driving oscillator circuitry comprised in the drive module to oscillate in resonance with a piezoelectric crystal mode that it drives. Each of the separate drive modules may be realized in hardware or software, for example in a proportional-integral-derivative (PID) control architecture. The different frequencies of the drive signals are tuned independently of the others, using the disclosed technique, to enable continuous vibration of the piezoelectric actuator at the selected multimode resonant mode. 
     In another embodiment, while driving the vibration, the drive modules modify the driving signal frequencies to follow the actuator&#39;s varying resonant frequencies by minimizing feedback signals. For example, in response to the different drive signals, a measured phase difference is minimized between different voltages across the piezoelectric actuator and respective currents flowing through the piezoelectric actuator. More formally, each module measures a phase difference, Δϕ, between the driving voltage V and the resulting current I outputted by the driving oscillator, and then minimizes Δϕ to maintain the oscillator driving the crystal mode in a resonance frequency into which it was tuned using the disclosed on-the-fly tuning technique. As noted above, another control mode is provided, that seeks to maximize admittance (minimize impedance) of the crystal. 
     System Description 
       FIG.  1    is a schematic, pictorial view, along with a side view, of a phacoemulsification system  10 , in accordance with an embodiment of the present invention. 
     As seen in the pictorial view of phacoemulsification system  10 , and in inset  25 , phacoemulsification probe  12  (e.g., a handpiece  12 ) comprises a needle  16  surrounded by an irrigation sleeve  56 . Needle  16  is hollow and its lumen is used as an aspiration channel. 
     Needle  16  is configured for insertion into a lens capsule  18  of an eye  20  of a patient  19  by a physician  15  to remove a cataract. The needle (and irrigation sleeve  56 ) are shown in inset  25  as a straight object. However, any suitable needle may be used with phacoemulsification probe  12 , for example, a curved or bent tip needle commercially available from Johnson &amp; Johnson Surgical Vision, Inc., Santa Ana, Calif., USA. 
     In the shown example, probe  12  includes a sensor  27  coupled with irrigation channel  43   a , and a sensor  23  coupled with aspiration channel  46   a . Channels  43   a  and  46   a  are coupled respectively to irrigation line  43  and aspiration line  46 . The sensor measurements (e.g., pressure, vacuum, and/or flow) are taken close to the proximal end of the handpiece where the irrigation outlet and the aspiration inlet are located, so as to provide processor  38  an accurate indication of the actual measurements occurring within an eye and provide a short response time to a control loop comprised in processor  38 . 
     As shown, during the phacoemulsification procedure, processor-controlled pump  24  comprised in a console  28  pumps irrigation fluid from an irrigation reservoir (not shown) via irrigation sleeve  56  to irrigate the eye. The fluid is pumped via irrigation tubing line  43  running from console  28  to probe  12 . Using sensors (e.g., as indicated by sensors  23  and/or  27 ), processor  38  controls a pump rate of irrigation pump  24  to maintain intraocular pressure within prespecified limits. 
     Eye fluid and waste matter (e.g., emulsified parts of the cataract) are aspirated via hollow needle  16  to a collection receptacle (not shown) by a processor-controlled aspiration pump  26  also comprised in console  28  and using aspiration tubing line  46  running from probe  12  to console  28 . In an embodiment, processor  38  controls an aspiration rate of aspiration pump  26  to maintain intraocular pressure (in case of sub-pressure indicated, for example, by sensor  23 ) within prespecified limits. 
     As further shown, phacoemulsification probe  12  includes a piezoelectric actuator  14  coupled to a horn (not shown) that drives needle  16  to vibrate in a resonant vibration mode, having a frequency f 0 , that is used to break a cataract into small pieces during a phacoemulsification procedure. Console  28  comprises a piezoelectric drive module  30 , coupled with the piezoelectric crystal using electrical wiring running in cable  33 . 
     Drive module  30 , which includes analog high-power filters/amplifiers/drivers (and has no control circuitry of its own in the shown embodiment) is controlled by a processor  38  that uses the drive signal or a small-amplitude monitoring signal (e.g., at a detuned frequency) via cable  33  and enables a mechanical resonance of actuator  14  to be monitored and followed using a control loop comprised in processor  38 , e.g., by the processor adjusting frequency f of a drive signal. As noted above, the frequency f may denote multiple frequencies when multi-resonant phacoemulsification vibration modes are implemented in probe  12 . To this end, a single drive module  30  may receive a superposition of several frequencies with different amplitudes and relative phases. 
     Therefore, processor  38  may convey one or more processor-controlled driving signals, each having frequency f and phase ϕ via cable  33  to, for example, maintain needle  16  at maximal vibration amplitude. The drive module may be realized in hardware or software, for example, in a proportional-integral-derivative (PID) control architecture. 
     In another embodiment, processor  38  is used for GUI, and for sending high-level commands to a drive-module that includes control circuitry to perform the disclosed method. 
     In the shown embodiment, processor  38  may receive user-based commands via a user interface  40 , which may include setting a vibration mode and/or frequency of the piezoelectric crystal, and setting or adjusting an irrigation and/or aspiration rate of the irrigation pump  24  and aspiration pump  26 . Processor  38  may receive user-based commands via a user interface  40 , which may include needle  16  stroke amplitude settings and turning on irrigation and/or aspiration. In an embodiment, the physician uses a foot pedal (not shown) as a means of control. For example, pedal position one activates only irrigation, pedal position two activates both irrigation and aspiration, and pedal position three adds needle  16  vibration. Additionally, or alternatively, processor  38  may receive the user-based commands from controls located in a handle  21  of probe  12 . 
     In an embodiment, user interface  40  and display  36  may be integrated into a touch screen graphical user interface. 
     Some or all of the functions of processor  38  may be combined in a single physical component or, alternatively, implemented using multiple physical components. These physical components may comprise hard-wired or programmable devices, or a combination of the two. In some embodiments, at least some of the functions of processor  38  may be carried out by suitable software stored in a memory  35  (as shown in  FIG.  1   ). This software may be downloaded to a device in electronic form, over a network, for example. Alternatively, or additionally, the software may be stored in tangible, non-transitory computer-readable storage media, such as optical, magnetic, or electronic memory. 
     The system shown in  FIG.  1    may include further elements, which are omitted for clarity of presentation. For example, physician  15  typically performs the procedure using a stereo microscope or magnifying glasses, neither of which are shown. Physician  15  may use other surgical tools in addition to probe  12 , which are also not shown in order to maintain clarity and simplicity of presentation. 
     One-or-More Piezoelectric Resonant System for Phacoemulsification Probe 
       FIG.  2    is a block diagram schematically describing a multi-channel piezoelectric drive system  100  for phacoemulsification system  10  of  FIG.  1   , in accordance with an embodiment of the present invention. 
     As seen, drive system  100  comprises multi-channel drive-modules  30   1 ,  30   2 , . . .  30   N , i.e., N≥1, each coupled to one or more split electrodes  50  of piezoelectric actuator  14  (which may comprise a multi-stack crystal  22 ) of phacoemulsification probe  12 , using electrical links running in cable  33 . 
     Multi-channel drive modules  30   1 ,  30   2 , . . .  30   N  are essentially analog units controlled by processor  38  to convey driving signals having resonant frequencies f 1 , f 2 , . . . f N  of a multi-resonance mode of piezoelectric actuator  14  to drive modules  30   1 ,  30   2 , . . .  30   N . The actuators are controlled by processor  38 , by, for example, minimizing detected respective phase differences, Δϕj, j=1, 2 . . . , N, to keep the complex-mode of the crystal in resonance, e.g., following commands from the processor. 
     In an alternative embodiment (not shown), the actuators are controlled by processor  38 , by, for example, minimizing impedances z 1 , z 2 , . . . z N  experienced by the drive system in the multi-resonance mode. 
     Processor  38  is further configured to connect at least a portion of drive-modules  30   1 ,  30   2 , . . .  30   N , using a switching circuitry  41  with different combinations of the one or more multiple-split electrodes  50  of piezoelectric actuator  14 , so as to vibrate needle  16  in synchrony in one of several prespecified trajectories. 
     The example illustration shown in  FIG.  2    is chosen purely for the sake of conceptual clarity.  FIG.  2    shows only parts relevant to embodiments of the present invention. While  FIG.  2    shows a multi-mode/multi-frequency scheme, the invention is just as applicable to phacoemulsification probes driven by a single-mode/single-frequency driving signal (e.g., to a phacoemulsification probes with a single crystal that vibrates in one longitudinal mode). 
     On-the-Fly Tuning of a Resonant Mode 
       FIG.  3    shows graphs of driving frequency and phacoemulsification handpiece power as a function of time, schematically describing an on-the-fly tuning of a resonant mode of probe  12  of  FIG.  1   , in accordance with an embodiment of the present invention. The disclosed graphs show how deriving the operating frequency comprises identifying a time of occurrence of a peak  303  in the measured tuning signal, and determining a frequency  305  of the tuning signal at the time of occurrence of the peak. 
     As seen in the driving frequency graph, on a first activation time  302  (e.g., the first time the foot pedal is pressed to activate the power/ultrasound) of handpiece  12  in a procedure, a frequency sweep of the tuning signal is performed for a very brief time duration  304 , i.e., 50 ms-100 ms, at very low initial power (as shown in the handpiece power graph). This is sufficient for processor  38 , which controls driving of handpiece  12 , to determine peak  303  in the low initial power (e.g., a peak in electrical current or in admittance) and determine frequency  305 , f 0i , required for piezoelectric actuator  14 , but the time is short enough so that it is unnoticeable to the surgeon activating the handpiece. 
     The graphs show the effects if the frequency sought is the resonant frequency. The graph of the driving frequency shows that after initial activation the frequency is swept from 38.5 KHz to 41.5 KHz during a time duration  304  of ˜100 ms. The graph of handpiece power shows that a very low power is used during the sweep, and that a peak  303  occurs at that low power. As seen, the processor determines the resonant frequency  305 , f 0i =39.8 KHz, corresponding to the peak  303  of the power graph. This frequency is then applied with the “full” power that the surgeon expects to use. The graphs further illustrate that there is then a very slight decrease in the frequency, and a small increase in the power, to a peak power  306 , until resonance at the desired power is achieved. As noted above, it typically takes slightly longer to find the optimal frequency at high power than at low power and, in parallel, to compensate in the amplitude of the driving signal to maintain the handpiece operating near the desired power. 
     Just after the initial parameter sweep, the handpiece is already operated very near its optimal parameters and the procedure is performed as usual by the surgeon. Whenever power ( 308 ) is reapplied to the handpiece during the procedure, an online tuning algorithm further optimizes the operating conditions of the handpiece, the optimized parameters maintained and automatically improved as needed throughout the procedure. 
       FIG.  4    is a flow chart schematically describing a method for on-the-fly tuning of a resonant mode of phacoemulsification probe  12  of  FIG.  1   , in accordance with embodiments of the present invention. The algorithm, according to the presented embodiment, carries out a process that begins with physician  15  pressing a foot pedal to clinically operate phacoemulsification probe  12 . To this end, physician  15  presses a foot pedal to activate the power to the phacoemulsification probe  12  (e.g., presses the foot pedal into a foot position 3 (FP3) and applies power based on the physician selected setting, e.g., panel, linear, desired duty cycle, etc.), at a probe power ramping-up step  402 . 
     During power ramping-up time, the duration of which is typically up to 100 mS, processor  38  performs on-the-fly frequency tuning of one or more resonant modes of piezoelectric actuator  14  inside handpiece  12 , at an on-the-fly tuning step  404 . The step includes identifying initial peak power  303  (or admittance, in another embodiment) and determining the corresponding frequency  305 , f 0i . 
     At a needle vibration controlling step  406 , one or more drive modules  30   1 ,  30   2 , . . .  30   N  measure the aforementioned phase differences between voltages and currents across and through piezoelectric actuator  14  (e.g., between split electrodes  50 ). 
     At a needle motion control step  408 , processor  38  of system  10  uses the phase information control step  406  to adjust frequencies of the drive signals such that piezoelectric actuator  14  vibrates at the multiple (selected) resonant frequencies, so as to continue vibrating needle  16  in a complex trajectory. 
     In a further embodiment, processor  38  uses a separate feedback loop on nominal power (other than that used for tracking a resonant frequency) to ensure that the power is kept approximately constant, at an independent power control step  410 . Namely, power control runs in parallel to frequency control (and the two controls may affect each other). As seen, steps  406 ,  408 ,  410  are performed continuously while the pedal is pressed during the actual procedure, not just when starting (e.g., also when normal power is applied, to fine tune the frequency). An example of such feedback loop is described above with respect to  FIG.  2   . 
     The example flow chart shown in  FIG.  4    is chosen purely for the sake of conceptual clarity. For example, additional steps such as irrigating the eye are omitted for simplicity and clarity of presentation. 
     Although the embodiments described herein mainly address phacoemulsification, the methods and systems described herein can also be used in other applications that may require a multi-channel piezoelectric resonant system to drive a moving member, such as ultrasonic blades, and other types of actuators. 
     It will thus be appreciated that the embodiments described above are cited by way of example, and that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and sub-combinations of the various features described hereinabove, as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art. Documents incorporated by reference in the present patent application are to be considered an integral part of the application except that to the extent any terms are defined in these incorporated documents in a manner that conflicts with the definitions made explicitly or implicitly in the present specification, only the definitions in the present specification should be considered.