US-12627043-B2 - Real time bur chatter compensation in surgical cutting burs

Abstract

A surgical console system configured to provide a drive signal to a surgical instrument for rotating a surgical bur. The surgical console system may supply a first drive signal to the surgical instrument to rotate the bur at a desired speed and to determine an electrical current drawn by the surgical instrument based on the drive signal. The surgical console system may be further configured to identify a chatter event based on the electrical current, and to supply a second drive signal to the surgical instrument based on the identified chatter event.

Inventors

• Michael Laubenthal

Assignees

• STRYKER CORPORATION

Dates

Publication Date

20260512

Application Date

20220301

Claims (20)

1. 1 . A surgical console system configured to provide a drive signal to a surgical instrument comprising a rotatable bur configured to contact a tissue surface, the surgical console system comprising: a processor and a memory, the memory storing instructions executable by the processor to: supply a first drive signal to the surgical instrument to rotate the bur at a rotational speed; determine an electrical current drawn by the surgical instrument based on the drive signal; identify a chatter event based on the electrical current, wherein the chatter event is characterized by undesirable vibration of the bur during contact between the tissue surface and the bur; and supply a second drive signal to the surgical instrument based on an identified chatter event.
2. 2 . The surgical console system of claim 1 , wherein the second drive signal supplied to the surgical instrument rotates the bur at an alternate speed.
3. 3 . The surgical console system of claim 1 , further comprising an instrument port configured to engage with a corresponding connector of the surgical instrument for communication with the surgical instrument.
4. 4 . The surgical console system of claim 1 , further comprising a step of receiving a user input signal corresponding to the rotational speed of the bur.
5. 5 . The surgical console system of claim 1 , wherein the instruction to identify a chatter event is further defined as analyzing the electrical current in a frequency domain to generate a harmonic signature.
6. 6 . The surgical console system of claim 4 , wherein the user input signal is received from a footswitch.
7. 7 . The surgical console system of claim 5 , wherein the harmonic signature is generated by transforming the electrical current from a time domain to the frequency domain using a Fourier transform.
8. 8 . The surgical console system of claim 5 , wherein the instruction to identify the chatter event further comprises comparing the harmonic signature to a chatter signature stored in the memory.
9. 9 . The surgical console system of claim 7 , wherein the instruction to identify the chatter event further comprises determining whether the harmonic signature is an n-th order harmonic of the rotational speed of the bur.
10. 10 . The surgical console system of claim 7 , wherein the instruction to determine the electrical current comprises calculating a flux vector of the surgical instrument.
11. 11 . The surgical console system of claim 8 , wherein the instruction to identify the chatter event further comprises selecting the chatter signature from a plurality of chatter signature based on a bur parameter.
12. 12 . The surgical console system of claim 8 , wherein the chatter signature stored in the memory is defined by a resonant peak.
13. 13 . The surgical console system of claim 11 , wherein the bur parameter is further defined as a bur geometry.
14. 14 . A surgical bur system capable of rotating a surgical bur at a speed of at least 5,000 RPM, the surgical bur system comprising: a handheld surgical instrument comprising: a body; a motor disposed in the body; a surgical bur coupled to the motor and configured to rotate relative to the body and contact a tissue surface; a console in communication with the handheld surgical instrument and configured to provide a drive signal to the motor, the console comprising: a processor and a memory, the memory storing instructions executable by the processor to: supply a first drive signal to the handheld surgical instrument to rotate the surgical bur at a rotational speed; determine an electrical current drawn by the handheld surgical instrument based on the drive signal; identify a chatter event based on the electrical current, wherein the chatter event is characterized by undesirable vibration of the bur during contact between the tissue surface and the bur; and supply a second drive signal to the handheld surgical instrument based on an identified chatter event.
15. 15 . The surgical bur system of claim 14 , wherein the second drive signal supplied to the handheld surgical instrument rotates the surgical bur at an alternate speed.
16. 16 . The surgical bur system of claim 14 , further comprising a user input in communication with the console configured to adjust the rotational speed of the surgical bur.
17. 17 . The surgical bur system of claim 14 , wherein the instruction to identify a chatter event is further defined as analyzing the electrical current in a frequency domain to generate a harmonic signature.
18. 18 . The surgical bur system of claim 17 , wherein the harmonic signature is generated by transforming the electrical current from a time domain to the frequency domain using a Fourier transform.
19. 19 . The surgical bur system of claim 17 , wherein adjusting the drive signal supplied to the handheld surgical instrument comprises calculating chatter frequency.
20. 20 . The surgical bur system of claim 19 , wherein adjusting the drive signal supplied to the handheld surgical instrument further comprises calculating a rotation speed that based on the chatter frequency that will not result in a chatter event.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS The subject patent application is the National Stage of International Patent Application No PCT/US2022/018325, filed on Mar. 1, 2022, which claims priority to, and all the benefits of, U.S. Provisional Patent Application No. 63/155,142, filed on Mar. 1, 2021, the entire contents of which are incorporated by reference herein. BACKGROUND Surgical burs often operate at speeds upwards of 5,000 RPM. At such speeds, vibration must be minimized at the contact between tissue and surgical bur. The bur itself is often designed to minimize this vibration, however, there is also a need for other aspects of the surgical bur system to further counter this vibration. It is the object of this disclosure to discuss methods by which the vibration may be countered in real time by the surgical bur system. SUMMARY In one aspect, a surgical console system configured to provide a drive signal to a surgical instrument comprising a rotatable bur. The surgical console system may comprise a processor and a memory. The memory may store instructions executable by the processor to supply a first drive signal to the surgical instrument to rotate the bur at a desired speed and to determine an electrical current drawn by the surgical instrument based on the drive signal. The memory may further store instructions to identify a chatter event based on the electrical current, and to supply a second drive signal to the surgical instrument based on the identified chatter event. In one implementation of this aspect, the second drive signal supplied to the surgical instrument may rotate the bur at an alternate speed. In another implementation of this aspect, the instruction to identify a chatter event is further defined as analyzing the electrical current to generate a harmonic signature. In another aspect, a surgical bur system capable of rotating a surgical bur at a speed of at least 5,000 RPM. The surgical bur system may comprise a handheld surgical instrument and a console in communication with the handheld surgical instrument. The handheld surgical instrument may comprise a body, a motor disposed in the body, and a surgical bur coupled to the motor and configured to rotate relative to the body. The console may be configured to provide a first drive signal to the motor. The console may comprise a processor and a memory. The memory may store instructions executable by the processor to supply a drive signal to the handheld surgical instrument to rotate the surgical bur at a desired speed and to determine an electrical current drawn by the handheld surgical instrument based on the drive signal. The memory may further store instructions to identify a chatter event based on the electrical current, and to supply a second drive signal to the handheld surgical instrument based on the identified chatter event. In one implementation of this aspect, the second drive signal supplied to the surgical instrument may rotate the bur at an alternate speed. In another implementation of this aspect, the instruction to identify a chatter event is further defined as analyzing the electrical current to generate a harmonic signature. Any of the above aspects can be combined in full or in part. Any features of the above aspects can be combined in full or in part. Any of the above implementations for any aspect can be combined with any other aspect. Any of the above implementations can be combined with any other implementation whether for the same aspect or a different aspect. BRIEF DESCRIPTION OF THE DRAWINGS Advantages of the present disclosure will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings. FIG. 1 is a perspective view of a handheld surgical instrument including a hub coupled to a nose tube assembly. FIG. 2A is a flow diagram representing an operating process of the handheld surgical instrument. FIG. 2B is a flow diagram representing a speed control process for the handheld surgical instrument. FIG. 2C is a flow diagram representing a current sensor process for the handheld surgical instrument. FIG. 2D is a flow diagram representing a chatter algorithm process for the handheld surgical instrument. FIG. 3 is a partially exploded view of a console-based surgical bur system comprising a console system, a plurality of surgical instruments, and a plurality of input devices. DETAILED DESCRIPTION Referring now to the drawings, a surgical console system 132 and a surgical bur system 120 having an operational control system for a surgical instrument 10 are disclosed. In particular, embodiments of the operational control mechanism may be suitable for use with a broad selection of instruments such as surgical drills, saws, and like devices. As one example, the surgical instrument 10 may comprise a specialty drill such as one sold under the brand name CORE UNIVERSAL SERIES by Stryker Instruments of Kalamazoo,