MEDICAL DEVICE INSPECTION SYSTEM

Abstract

A medical device inspection system may include a base, a medical device holder on the base, a fiber scope holder on the base, a moveable roller moveably attached to the base such that it is free to rotate around an axis and move from a first position to a second position along the base, and a feeder coupled with the base for feeding a flexible portion of the fiber scope into a lumen of the medical device. During use, the flexible portion of the fiber scope may extend from the handle, around the moveable roller, and through the feeder to enter an opening in the lumen of the medical device.

Claims

1-51. (canceled)

52. An inspection system for inspecting a lumen of a medical device, the inspection system comprising: a fiber scope having a distal end and a proximal end, the distal end including a camera configured to capture images of the lumen of the medical device; and a processor loaded with a learning algorithm trained on training images of medical device lumens with irregularities, the learning algorithm configured to receive data from the camera to identify one or more irregularities in the lumen of the medical device.

53. The inspection system of claim 52, further comprising: a medical device holding member for holding the medical device; a fiber scope holder configured to receive a proximal end of the fiber scope; a pair of opposed rotatable drums for moving the distal end of the fiber scope relative to the lumen of the medical device; and a translatable roller configured to both rotate and slide relative to the pair of opposed rotatable drums to take up slack in the fiber scope as the fiber scope is moved through the lumen of the medical instrument.

54. The inspection system of claim 52, wherein the one or more irregularities comprise at least one of contaminants, bacteria, gouges, kinks, cracks, or moisture.

55. The inspection system of claim 52, wherein the processor is further configured to capture an image of the one or more irregularities in the lumen of the medical device.

56. The inspection system of claim 52, wherein the processor is further configured to determine a location of each irregularity of the one or more irregularities in the form of the distance of the irregularity from a distal opening of the lumen.

57. The inspection system of claim 52, wherein the processor is further configured to store identifying information about the type and location of each irregularity in a controller.

58. The inspection system of claim 52, wherein the processor is configured to label the one or more irregularities with an indicator light.

59. The inspection system of claim 52, wherein the processor is further configured to activate an ultraviolet light source in response to an identified irregularity.

60. The inspection system of claim 52, wherein the processor loaded with the learning algorithm is located at a base of the inspection system.

61. The inspection system of claim 53, wherein the processor is further configured to provide drive instructions to the pair of opposed rotatable drums to move the distal end of the fiber scope relative to the lumen of the medical device.

62. The inspection system of claim 53, wherein movement of the distal end of the fiber scope relative to the lumen of the medical device is performed manually.

63. A method for inspecting a lumen of a medical device, comprising: holding the medical device using a medical device holding member; using a fiber scope having a distal end and a proximal end, where the distal end includes a camera configured to capture images of the lumen of the medical device; receiving the proximal end of the fiber scope in a fiber scope holder; moving the distal end of the fiber scope relative to the lumen of the medical device using a pair of opposed rotatable drums; taking up slack in the fiber scope as the fiber scope is moved through the lumen of the medical instrument using a translatable roller that is configured to both rotate and slide relative to the pair of opposed rotatable drums; and using a processor loaded with a learning algorithm trained on training images of medical device lumens with irregularities, where the learning algorithm is configured to receive data from the camera to identify one or more irregularities in the lumen of the medical device.

64. The method of claim 63, wherein the one or more irregularities comprise at least one of contaminants, bacteria, gouges, kinks, cracks, or moisture.

65. The method of claim 63, wherein the processor is further configured to capture an image of the one or more irregularities in the lumen of the medical device.

66. The method of claim 63, wherein the processor is further configured to determine a location of each irregularity of the one or more irregularities in the form of the distance of the irregularity from a distal opening of the lumen.

67. The method of claim 63, wherein the processor is further configured to store identifying information about the type and location of each irregularity in a controller.

68. The method of claim 63, wherein the processor is configured to label the one or more irregularities with an indicator light.

69. The method of claim 63, wherein the processor is further configured to activate an ultraviolet light source in response to an identified irregularity.

70. The method of claim 63, wherein movement of the distal end of the fiber scope relative to the lumen of the medical device is performed manually.

71. A medical device inspection system comprising: a medical device holding member configured to receive an elongated flexible medical device defining a lumen to be visually inspected; a flexible borescope having a distal end and a proximal end, the distal end including a camera configured to capture images of the lumen of the elongated flexible medical device; and an apparatus configured enabling relative movement between the flexible borescope and the medical device to progress the camera of the flexible borescope through the lumen of the elongated flexible medical device, the apparatus including, a borescope holding member, the borescope holding member configured to receive a proximal end of the flexible borescope; a pair of opposed rotatable drums, the pair of opposed rotatable drums configured to receive a portion of the flexible borescope therebetween; and a translatable roller over which a portion of the flexible borescope is positioned, wherein the translatable roller is moveable relative to the borescope holding member and the pair of opposed rotatable drums to take up slack in the flexible borescope as the flexible borescope passes through the pair of opposed rotatable drums.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 is a diagrammatic representation of one example of a medical device inspection system;

[0019] FIG. 2 is a diagrammatic representation of another example of a medical device inspection system;

[0020] FIG. 3 is a diagrammatic representation of another example of a medical device inspection system;

[0021] FIG. 4 is a diagrammatic representation of another example of a medical device inspection system;

[0022] FIG. 5 is a diagrammatic representation of example shapes of an interior of a lumen of a medical endoscope, illustrating a method according to one example; and

[0023] FIG. 6 is a flow diagram of a method of inspecting a medical device, according to one example.

DETAILED DESCRIPTION OF THE INVENTION

[0024] Disclosed in this application are various examples of a medical device inspection system and method. In general, the system and method provide for automatic feeding of a fiber scope into the lumen of a medical device in order to inspect the medical device. Feeding of the fiber scope may be done in a stepwise fashion, images may be captured at specified intervals, and the locations of the intervals may be recorded. In some embodiments, artificial intelligence may be used to help the operator of the system identify imperfections in the lumen of the medical device, such as contaminations and defects. These concepts and many others are described in greater detail below. The examples described herein are not intended to limit the scope of the invention but are provided for descriptive purposes only.

[0025] Referring now to FIG. 1, in one example, a medical device inspection system 10 may include a base 12 (or “tower,” in the case of a vertical arrangement, as shown in FIG. 1) and multiple components attached to or embedded in base 12. This embodiment of system 10 is shown with the bottom of base 12 resting on a flat surface 32, such as a table. In another example, system 10 may be flipped, so that base 12 hangs from a ceiling or other elevated structure. In yet another example, base 12 may lie flat on surface 32. Attached to base 12 is a moveable roller 14, which is free to rotate about its central axis of rotation 15 and also move back and forth along a longitudinal axis 17 of base 12. Also attached to base 12 is a fiber scope handle attachment member 19, by which a fiber scope handle 16 is attached to base 12. Handle attachment member 19 may be multiple clips (as shown), clamps or any other suitable attachment structure(s).

[0026] Regarding the fiber scope shown in FIG. 1 and subsequent figures, the term “fiber scope” is used in this application to mean any type of elongate, flexible scope device, including a fiber optic scope and/or a digital scope. The fiber scope is shown as including a handle 16, which may include a processor and a light source for the scope, and a flexible, image capturing portion 18, which passes around moveable roller 14 to a feeder 20, which is also attached to base 12. Image capturing portion 18 may include a sheath, one or more fiber optic fibers, a “camera on a chip,” such as a CMOS camera and/or the like. In some embodiments (for example, the one shown in FIG. 4), the scope may not include a handle but may house the light source and processor elsewhere.

[0027] Feeder 20 includes a first spinning drum 22 and a second spinning drum 24. One of the two drums 22, 24, in this example first drum 22, is connected to a drive mechanism or motor, which spins the first drum 22 about its axis. Second drum 24 spins freely when pressure from first drum 22 is applied to it and motor spins first drum 22. Feeder 20 also includes a tensioner 28 for adjusting an amount of tension between the two surfaces of the two drums 22, 24 against one another. System 10 also includes a medical device attachment clamp 26 (or other attachment member) coupled with base 12, for attaching medical device 30 to system 10. Neither medical device 30 nor surface 32 is typically part of system 10, but they are illustrated for exemplary purposes. Finally, system 10 may include a display and control module 13 (or multiple modules). Module 13 may include a display portion, such as a video monitor with or without touch screen capabilities. Module 13 may also include one or more controls for controlling feeder 20, controlling the fiber scope and the like. The display portion of module 13 may show images taken with the fiber scope, indicator light(s) signifying a contaminated or damaged area in the lumen of medical device 30, information about a contamination or damaged area in medical device 30, identifying information identifying medical device 30 and/or any other suitable information.

[0028] In use, handle 16 is attached to handle attachment member 19, and flexible scope portion 18 is passed around moveable roller and through drums 22, 24. Tensioner 28 is adjusted to adjust the tension placed on flexible portion 18 by drums 22, 24. In one embodiment, the contact (outer) surfaces of drums 22, 24 may be made of nylon or other polymer and may be somewhat compliant, to better advance flexible portion 18 without damaging it. Medical device 30 is attached to clamp 26, and the distal end of flexible portion 18 is advanced into an opening in a lumen at the distal end of medical device 30. Feeder 20 then feeds flexible portion 18 of the fiber scope farther and farther into the lumen of medical device, until the entire device 30 (or a desired portion of device 30) is inspected. As fiber scope 18 advances, it may take multiple still images and/or video images of the lumen. As more and more of fiber scope 18 is advanced into medical device 30, moveable roller 14 moves longitudinally (or “translates”) along base 12 from a first position (solid-lined version at the top of FIG. 1) to a second position (dotted-line version at the bottom of FIG. 1), to accommodate for the shorter amount of flexible portion 18 between handle 16 and medical device 30. At the same time, moveable roller 14 also rotates around its rotational axis 15. As illustrated, in the second position, roller 14 is closer to handle 16 and feeder 20 than in the first position. Once flexible portion 18 has been advanced as far into medical device 30 as desired, it is retracted by handle 16, roller 14 and feeder 20, and roller 14 moves back to the first position from the second position.

[0029] Control and display module 13 may include any type of computing device, including a processor, and the processor may contain instructions for driving feeder 20 and/or the fiber scope. For example, in some embodiments, the drive mechanism of feeder 20 may be a step motor, and the controller may control incremental advancement of flexible portion 18 into medical device 30 via feeder 20. In some examples, the processor may include an artificial intelligence chip or other mechanism for artificial intelligence. Artificial intelligence may be used, for example, to allow the processor to identify irregularities inside the lumen of medical device 30 in images of the lumen captured by the fiber scope. For example, the processor may be able to identify contaminants, gouges, kinks, cracks, moisture and/or the like inside medical device 30. This identification may be enhanced via artificial intelligence, where the processor has been “taught” to detect irregularities by learning images of similar irregularities in other medical devices. In some embodiments, the processor may be used to detect an irregularity in the lumen during advancement, instruct the fiber scope to capture an image of the irregularity, determine a location of the irregularity in the form of a distance of the irregularity from a distal opening of the lumen, and store identifying information about the type and location of the irregularity in the controller. The controller may also store additional information, such as the type of medical device 30 being examined, the date, the time, the identity of the personnel conducting the examination, how many times the particular fiber scope has been used to inspect medical devices, and/or the like. In some embodiments, feeder 20 feeds flexible portion 18 into medical device 30 in predetermined increments, and an image is taken by the fiber scope at each increment. In other embodiments, the fiber scope may take continual video footage throughout the advancement, and the scope may also take still images at any identified areas of irregularity. Virtually any combination of fiber scope advancement and image capture is possible, and the controller/processor of system 10 may be capable of controlling any of a large number of different protocols.

[0030] Additionally, system 10 may be used to inspect any suitable medical or surgical device. The types of devices may include endoscopes of any kind, catheters, flexible instruments with lumens or channels, or virtually any other type of device with an inner portion that is hard to inspect visually from outside the device. System 10 may also have a number of different sizes and shapes in different examples. In the example of FIG. 1, when roller 14 moves all the way to the second position (dotted lines), it may be necessary to have about 12 inches of extra flexible portion 18 of the fiber scope, in order to extend from the distal end of handle 16, around roller 14, through feeder 20 and into the distal end of medical device 30. Other examples of system 10 may require shorter or longer segments of flexible portion.

[0031] Referring now to FIG. 2, another example of a medical device inspection system 50 is illustrated diagrammatically. FIG. 2 does not illustrate a base, tower or platform of system 50, and it also does not show the control/display module, but these features may be the same as, or similar to, those shown in FIG. 1, with the exception that the overall system 50 is L-shaped. Similar to the example of FIG. 1, system 50 includes a moveable roller 54, which is rotatable about its own axis 55 and also slidable along a longitudinal axis 57 from a first position to a second position (and back). Roller 54 may be spring loaded (same as in the previous example), so that when it is not under tension it returns to the first position. System 50 also includes a fiber scope with a handle 56 and a flexible portion 58, as well as a feeder 60 with a first spinning drum 62, a second spinning drum 64, a tensioner 68 and a medical device clamp 66, all as described above. A medical device 70 is typically not part of system 50, but rather is the item inspected by system 50.

[0032] The main difference between system 50 of FIG. 2 and system 10 of FIG. 1 is that the former includes a second, fixed-location roller 52, about which flexible portion 58 of the fiber scope wraps. This allows the two rollers 52, 54 to act as two pulleys, which may enhance feeding of flexible portion into medical device 70. This example may require a longer extra portion of flexible portion than in the previous example, such as about 14 inches to about 16 inches in one example. In all other respects, system 50 may share any or all of the characteristics and features of system 10 described above.

[0033] Referring now to FIG. 3, another example of a medical device inspection system 100 is illustrated diagrammatically. FIG. 3 also does not illustrate a base, platform or tower for holding system 100, but it may be similar to that shown in FIG. 1, with the exception that the overall system 100 has a three-prong (or triangular) shape. Similar to the example of FIG. 2, system 100 includes a moveable roller 104, which is rotatable about its own axis 105 and also slidable along a longitudinal axis 107 from a first position to a second position (and back). Roller 104 may be spring loaded, as described previously. System 100 also includes a fiber scope with a handle 106 and a flexible portion 108, as well as a feeder 110 with a first spinning drum 112, a second spinning drum 114, a tensioner 118 and a medical device clamp 116, all as described above. A medical device 120 is typically not part of system 100, but rather is the item inspected by system 100.

[0034] Like system 50 of FIG. 2, system 100 of FIG. 3 includes a second, fixed-location roller 102, about which flexible portion 108 of the fiber scope wraps. Additionally, system 100 includes a fixed cylinder 122, about which flexible portion 108 also wraps. In this example, fixed cylinder 122 does not rotate but merely acts as a third surface about which flexible portion 108 curves, thus providing system 100 with effectively three pulleys. This example may require about 12 inches of extra flexible portion 108 in one example. In all other respects, system 100 may share any or all of the characteristics and features of systems 10 and 50 described above.

[0035] Referring now to FIG. 4, another example of a medical device inspection system 150 is illustrated diagrammatically. This example of system 150 includes a base 152 and one large roller 154, which rotates about its own axis 155 but is fixed relative to base 152 (e.g., it does not move laterally along base 152). In this embodiment, the fiber scope is housed within roller 154. The processor and light source that are housed in a handle in other embodiments are housed somewhere within roller 154, and the flexible portion 158 is also housed in roller 154 in a spool-like fashion. To advance flexible portion 158 of the fiber scope into medical device 170, roller 154 rotates to unspool flexible portion 158. As in previous embodiments, system 150 also includes a display and control module 153 and a feeder 160 with a first spinning drum 162, a second spinning drum 164, a tensioner 168 and a medical device clamp 166, all as described above. A medical device 170 is typically not part of system 150, but rather is the item inspected by system 150.

[0036] The main difference between system 150 of FIG. 4 and previously described embodiments is roller 154, and the housing of the fiber scope in roller 154. In all other respects, system 150 may share any or all of the characteristics and features the previously described embodiments.

[0037] Referring now to FIG. 5, as mentioned briefly above, in some examples the medical device inspection system may include a computer processor with artificial intelligence capabilities and/or instructions for running an algorithm, either or both of which may allow the system to identify abnormalities within a medical device and even label the abnormalities according to types. For example, the system processor may be able to learn multiple shapes of medical device lumens and identify abnormalities by shape. FIG. 5 illustrates just several examples of such learned shapes. These examples include normal 200, kinked 202 (or oval), wet 204 (signifying accumulated moisture in the device), gouged 206, debris 208 (which could include contamination) and unidentified 210. The last of these—unidentified 210—could be a shape or collection of shapes that the system processor is able to identify as abnormal but is not able to assign to a particular category.

[0038] In various examples, the system may do any or all of the following. (1) The feeder may advance the camera through the medical device lumen in stepwise fashion or continuously until the system identifies an abnormality in the lumen, at which point the system may automatically stop advancing the camera and capture a video or still image of the area with the abnormality. (2) The system may identify the abnormality in the lumen based on learned shapes of images of medical device lumens stored in the system's processor. (3) The system may display the irregularity on the system display with some kind of label, such as a word description and/or an indicator light. (4) The system may provide other information about the irregularity, such as its location in the lumen (a distance from one end of the medical device, for example). (5) The system may automatically emit a UV light to disinfect an identified contamination in the lumen. Any combination of these activities, as well as others, may be performed by the system.

[0039] Referring now to FIG. 6, one example of a method 250 for inspecting a medical device, such as a lumen (or “channel”) of an endoscope is described. According to one example, a method 250 for inspecting an inside of a medical device may first involve setting up 252 or positioning the fiber scope on or in the medical device inspection system. This step of setting up 252 may include, for example, positioning a flexible fiber scope around a portion of a first roller of a medical device inspection system, such that a handle of the flexible fiber scope is positioned on one side of the first roller and a feeder of the medical device inspection system is on an opposite side of the roller. The method 250 may then involve positioning the flexible fiber scope through the feeder and advancing 254 a distal end of the flexible fiber scope into an opening in a lumen of the medical device. Next, the distal end of the flexible fiber scope is advanced farther into the lumen of the medical device, using the feeder. In some embodiments, all advancement 254 of the fiber scope into the medical device is done through the feeder. Alternatively, the initial advancement 254 may be performed manually, and subsequent advancement 254 may be with the feeder. This advancement 254, in some examples, causes the first roller to turn around an axis and move along the medical device inspection system toward the handle and the feeder. In other embodiments, the first roller does not move along the medical device.

[0040] The method may further include identifying an abnormality 256 in the medical device lumen. This identification step may be achieved using the processor, and in some cases artificial intelligence, of the system. Finally, the method may include capturing at least one image 258 of the lumen of the medical device with the flexible fiber scope. This image capturing step 258 may be done automatically in some examples, where the processor identifies the abnormality and sends a signal to the camera to capture the image 258.

[0041] In some examples, the method also includes attaching the medical device to the medical device inspection system before advancing the distal end of the fiber scope into the lumen. In some embodiments, positioning the flexible fiber scope through the feeder may involve positioning the flexible fiber scope between a first spinning drum and a second spinning drum of the feeder. Some embodiments may further include adjusting a tensioner of the medical device inspection system to adjust an amount of force applied to the flexible fiber scope by the first and second spinning drums. Advancing the distal end of the flexible fiber scope farther into the lumen of the medical device may sometimes be performed automatically by the feeder in a stepwise fashion.

[0042] Some examples of the method may include recording, with the medical device inspection system, multiple distances into the lumen of the medical device at which images are captured by the flexible fiber scope. In some examples, a controller (or processor) of the medical device inspection system instructs the flexible fiber scope to acquire at least one image. In some examples, the method may include distinguishing, from an image captured by the fiber scope, that the lumen contains a defect, and instructing the feeder and/or the fiber scope to record a location of the defect in the lumen. Some examples may involve determining a distance from the opening in the lumen to a defect in the lumen, using a processor of the medical device inspection system.

[0043] Some examples of the method involve using artificial intelligence in the medical device inspection system to determine that the lumen contains the defect. Some examples of the method involve using the artificial intelligence to distinguish differently labeled shapes within the lumen of the medical device, where the differently labeled shapes may include normal, gouged, oval, wet and debris-containing. The artificial intelligence may also be used to record an image, a location, a description, a date, a time, a name of a person operating the system, and/or a recommended course of corrective action pertaining to an identified defect in the lumen of the medical device.

[0044] In some examples, the method may involve attaching the handle of the fiber scope to the medical device inspection system. Some embodiments may involve positioning the flexible fiber scope around a first fixed roller fixedly attached to the medical device inspection system between the roller and the feeder. Some examples may involve positioning the flexible fiber scope around a second fixed roller fixedly attached to the medical device inspection system between the roller and the handle of the flexible fiber scope.

[0045] In some embodiments, the method may involve emitting ultraviolet light from the flexible fiber scope onto a contaminated portion of the lumen of the medical device to help treat the contaminated portion. Alternatively, any other type or wavelength of light may be emitted to treat a contaminated area in a medical device. Light may alternatively or additionally be emitted to help identify an area of damage or contamination in the medical device lumen. For example, chemoluminescence may be used in some examples. In some examples, the method may also include diffusing the ultraviolet light (or other form of light) with a light diffuser before emitting it from the flexible fiber scope. In some embodiments, emitting the ultraviolet light involves emitting pulsed light.

[0046] The method may also involve preventing kinking of the flexible fiber scope by housing a laser fiber in a sheath of the flexible fiber scope. The method may also involve preventing the flexible fiber scope from being used more than a predetermined number of times by including a lock-out feature in the medical device inspection system. The method may also involve preventing the flexible fiber scope from being used with unapproved medical devices or by unapproved inspection personnel by including a lock-out feature in the medical device inspection system. The method may also involve sensing an amount of torque applied to the flexible fiber scope by the medical device inspection system to prevent applying excessive force to the flexible fiber scope.

[0047] The above description is intended to be complete and accurate. It is meant to be a description of various embodiments, however, and is not intended to limit the scope of the invention. Various changes may be made to any of the embodiments described above, without departing from the scope of the invention described in the following claims. For example, features of one embodiment may be combined with a different embodiment, the order of steps in a given method may be changed, or the like.