Intravascular imaging catheter system with force error detection and automatic remediation via pullback and rotation for translating and rotating a torque cable in a catheter

1. A pullback and rotation unit for axially translating and rotating a torque cable in an elongate outer sheath of a catheter, the pullback and rotation unit comprising:

a housing with a longitudinal axis;

a rotor disposed in the housing and mounted to rotate and linearly translate relative to the longitudinal axis of the housing, the rotor further being configured to be coupled with a proximal end of the torque cable;

a plurality of sensors configured on the rotor and radially spaced from an axis of rotation of the rotor and configured to provide an output indicative of an axial force exerted by the torque cable on the rotor;

wherein the rotor includes a main body and a coupling mounted on the main body of the rotor, wherein the coupling is configured to couple with the proximal end of the torque cable, and wherein each of the plurality of sensors is mounted between the coupling and the main body of the rotor;

wherein the coupling is mounted to be movable longitudinally relative to the main body of the rotor

wherein the output is an average of an output from each of the plurality of sensors over a period of time for at least one full rotation of an imaging tip located at a distal end of the torque cable;

a controller configured to, when the output exceeds a predetermined threshold, cause the rotor to automatically perform a remedial action to relieve at least a portion of the axial force, wherein the controller is configured to cause the rotor, when performing the remedial action, to retract proximally a predetermined distance; and

wherein the predetermined threshold is set below a level at which damage to the outer sheath will occur due to a distal end of the torque cable being unable to traverse a portion of the outer sheath.

2. The pullback and rotation unit of claim 1 , wherein each of the plurality of sensors is mounted on the main body of the rotor.

3. The pullback and rotation unit of claim 1 , wherein the plurality of sensors includes at least three sensors.

4. The pullback and rotation unit of claim 3 , wherein the at least three sensors are radially spaced equiangularly about the axis of rotation of the rotor.

5. The pullback and rotation unit of claim 1 , wherein the predetermined threshold is set below 10N.

6. The pullback and rotation unit of claim 1 , wherein the predetermined threshold is between 2N and 6N.

7. The pullback and rotation unit of claim 1 , wherein the predetermined distance is sufficient to relieve at least the portion of the axial force applied to the rotor by the torque cable.

8. The pullback and rotation unit of claim 1 , wherein the controller is configured to cause the rotor, when performing the remedial action, to continue rotating as it is retracted proximally the predetermined distance.

9. The method of claim 1 , wherein the plurality of sensors are each configured to provide an output indicative of an axial force exerted by the torque cable on the rotor parallel to the axis of the rotation of the rotor.

10. An intravascular imaging catheter system comprising:

a pullback and rotation unit for axially translating and rotating a torque cable in an elongate outer sheath of a catheter, the pullback and rotation unit comprising:

a housing with a longitudinal axis;

a rotor disposed in the housing and mounted to rotate and linearly translate relative to the longitudinal axis of the housing, the rotor further being configured to be coupled with a proximal end of the torque cable;

a plurality of sensors configured on the rotor and radially spaced from an axis of rotation of the rotor and configured to provide an output indicative of an axial force exerted by the torque cable on the rotor;

wherein the output is an average of an output from each of the plurality of sensors over a period of time for at least one full rotation of an imaging tip located at a distal end of the torque cable;

a controller configured to, when the output exceeds a predetermined threshold, cause the rotor to automatically perform a remedial action to relieve at least a portion of the axial force, wherein the controller is configured to cause the rotor, when performing the remedial action, to retract proximally a predetermined distance; and

wherein the predetermined threshold is set below a level at which damage to the outer sheath will occur due to a distal end of the torque cable being unable to traverse a portion of the outer sheath; and

an imaging catheter including an elongate outer sheath having a proximal end coupled with the housing, the torque cable being disposed in the outer sheath and having a proximal end coupled with the rotor, and an imaging tip located at a distal end of the torque cable and including at least one imaging component selected from the group consisting of an optical element and an ultrasonic transducer.

11. The intravascular imaging catheter system of claim 10 , wherein the plurality of sensors are each configured to provide an output indicative of an axial force exerted by the torque cable on the rotor parallel to the axis of the rotation of the rotor.

12. A method of imaging a vessel using an intravascular imaging catheter system, comprising:

a pullback and rotation unit for axially translating and rotating a torque cable in an elongate outer sheath of a catheter, wherein the pullback and rotation unit comprises:

a housing with a longitudinal axis;

a rotor disposed in the housing and mounted to rotate and linearly translate relative to the longitudinal axis of the housing, the rotor further being configured to be coupled with a proximal end of the torque cable;

a plurality of sensors configured on the rotor and radially spaced from an axis of rotation of the rotor and configured to provide an output indicative of an axial force exerted by the torque cable on the rotor;

wherein the output is an average of an output from each of the plurality of sensors over a period of time for at least one full rotation of an imaging tip located at a distal end of the torque cable;

a controller configured to, when the output exceeds a predetermined threshold, cause the rotor to automatically perform a remedial action to relieve at least a portion of the axial force, wherein the controller is configured to cause the rotor, when performing the remedial action, to retract proximally a predetermined distance; and

wherein the predetermined threshold is set below a level at which damage to the outer sheath will occur due to a distal end of the torque cable being unable to traverse a portion of the outer sheath; and

an imaging catheter including an elongate outer sheath having a proximal end coupled with the housing, the torque cable being disposed in the outer sheath and having a proximal end coupled with the rotor, and an imaging tip located at a distal end of the torque cable and including at least one imaging component selected from the group consisting of an optical element and an ultrasonic transducer;

the method comprising: coupling the proximal end of the elongate outer sheath with the housing of the pullback and rotation unit;

coupling the proximal end of the torque cable with the rotor disposed within the housing of the pullback and rotation unit;

inserting the catheter into the vessel;

linearly translating the imaging tip distally relative to the outer sheath by linearly translating the rotor distally in the housing of the pullback and rotation unit;

receiving an output from at least one sensor indicative of an axial force applied to the rotor by the torque cable; and

based on the output from the at least one sensor exceeding a predetermined threshold, causing the rotor to automatically perform a remedial action to relieve at least a portion of the axial force wherein causing the rotor, when performing the remedial action, to retract proximally a predetermined distance;

wherein the predetermined threshold is set below a level at which damage to the outer sheath will occur due to the distal end of the torque cable being unable to traverse a portion of the outer sheath.

13. The method of claim 12 , wherein the predetermined distance is sufficient to relieve at least the portion of the axial force applied to the rotor by the torque cable.

14. The method of claim 12 , wherein, when performing the remedial action, the rotor is caused to continue rotating as it is retracted proximally the predetermined distance.

15. The method of claim 12 , wherein the predetermined threshold corresponds to a force greater than an average axial force applied to the rotor during normal operation of the catheter.

16. The method of claim 12 , wherein the plurality of sensors are each configured to provide an output indicative of an axial force exerted by the torque cable on the rotor parallel to the axis of the rotation of the rotor.