Systems and methods of calibrating operating parameters of negative pressure wound therapy apparatuses

1. A negative pressure pump system comprising:

a pump assembly comprising:

an actuator;

a diaphragm configured to be moved by the actuator;

a chamber housing at least one valve; and

at least one mechanical stop associated with maximum movement of the diaphragm away or toward the chamber; and

a controller configured to control operation of the pump assembly, the controller further configured to:

calculate at least one of an amplitude or an offset for a drive signal based at least in part on previously calculated parameters determined during calibration of the pump assembly and a negative pressure setting, the calibration comprising measuring a linear position of the diaphragm and determining, based on the linear position of the diaphragm, the previously calculated parameters that prevent contact of at least one of the actuator or the diaphragm with the at least one mechanical stop during movement of the diaphragm, the previously calculated parameters comprising a plurality of amplitudes and offsets determined for a plurality of negative pressure settings;

generate the drive signal with the at least one calculated amplitude or offset; and

apply the drive signal to the actuator to cause movement of the diaphragm, thereby causing delivery of negative pressure wound therapy to a patient.

2. The negative pressure pump system of claim 1 , wherein the controller is further configured to calculate both the amplitude and the offset for the drive signal.

3. The negative pressure pump system of claim 1 , wherein the controller is further configured to interpolate between at least two previously calculated amplitudes or offsets.

4. The negative pressure pump system of claim 3 , wherein the controller is further configured to linearly interpolate between at least two previously calculated amplitudes or offsets.

5. The negative pressure pump system of claim 1 , wherein the previously calculated parameters are dependent on one or more properties of at least one of the actuator or the diaphragm of the pump assembly.

6. The negative pressure pump system of claim 1 , wherein the actuator comprises a voice coil actuator, the voice coil actuator being connected to the diaphragm.

7. The negative pressure pump system of claim 1 , wherein the pump assembly further comprises a spring configured to affect a resonant frequency of the pump assembly.

8. The negative pressure pump system of claim 1 , wherein the controller is further configured to apply a start-up drive signal when the pump assembly has been activated after a period of inactivity, the start-up drive signal comprising at least one of an amplitude or an offset different from at least one of the amplitude or the offset of the drive signal.

9. The negative pressure pump system according to claim 8 , wherein the controller is further configured to:

calculate at least one of an amplitude or an offset for the start-up drive signal based at least in part on previously calculated parameters and a soft start negative pressure setting that is less than the negative pressure setting; and

apply the start-up drive signal to the actuator.

10. The negative pressure pump system according to claim 9 , wherein the controller is further configured to apply the start-up drive signal to the actuator over a start-up time period until the soft start negative pressure setting is reached in a fluid flow path connecting the pump assembly to a wound dressing placed over a wound, and subsequently apply the drive signal to the pump assembly.

11. The negative pressure pump system according to claim 10 , wherein the controller is configured to apply the drive signal to actuator until the negative pressure setting is reached in the fluid flow path.

12. The negative pressure pump system according to claim 10 , wherein the start-up time period is approximately 100 milliseconds, between approximately 10 milliseconds and approximately 1000 milliseconds, between approximately 50 milliseconds and approximately 500 milliseconds, or between approximately 75 milliseconds and approximately 250 milliseconds.

13. The negative pressure pump system of claim 1 , wherein:

the pump assembly is configured to maintain negative pressure in a fluid flow path connecting the pump assembly to a wound between a high negative pressure setting and a low negative pressure setting; and

the previously calculated parameters comprise at least one of an amplitude or an offset for the drive signal determined for pressure settings corresponding to the low negative pressure setting and the high negative pressure setting.

14. The negative pressure pump system of claim 13 , wherein the previously calculated parameters further comprise at least one of an amplitude or an offset for the drive signal determined for an initial pressure setting in the fluid flow path.

15. The negative pressure pump system of claim 1 , wherein the linear position of the diaphragm is not measured during the delivery of negative pressure wound therapy to the patient.

16. The negative pressure pump system of claim 15 , wherein calibration comprises measuring the linear position of the diaphragm with an external sensor.

17. A method for controlling a pump system configured for negative pressure wound therapy, the method comprising:

calculating at least one of an amplitude or an offset for a drive signal based at least in part on previously calculated parameters determined during calibration and a target negative pressure setting, the calibration comprising measuring a linear position of a diaphragm of the pump system and determining, based on the linear position of the diaphragm, the previously calculated parameters that prevent contact of at least one of an actuator of the pump system or the diaphragm with at least one mechanical stop of the pump system, the previously calculated parameters comprising a plurality of amplitudes and offsets determined for a plurality of negative pressure settings;

generating the drive signal with the at least one calculated amplitude or offset; and

applying the drive signal to the pump system, thereby causing delivery of negative pressure wound therapy to a patient,

wherein the method is performed under control of a controller of the pump system.

18. The method of claim 17 , wherein calculating the at least one of the amplitude or the offset for the drive signal comprises interpolating between at least two calibrated amplitudes or offsets in response to determining that the target negative pressure setting is not included in the plurality of negative pressure settings.

19. The method of claim 17 , further comprising maintaining negative pressure in a fluid flow path connecting the pump system to a wound between a high negative pressure setting and a low negative pressure setting, wherein the previously calculated parameters comprise at least one of an amplitude or an offset for the drive signal determined for the low negative pressure setting and the high negative pressure setting.

20. The method of claim 17 , wherein the linear position of the diaphragm is not measured during the delivery of negative pressure wound therapy to the patient.

21. The method of claim 20 , wherein calibration comprises measuring the linear position of the diaphragm with an external sensor.