Methods and devices for occlusion detection using actuator sensors

1. A method of detecting an occlusion in a fluid path, the method comprising:

operating, by a control module of an infusion device, a driver module to provide energy to an actuation arrangement to achieve a commanded actuation state, wherein the actuation arrangement is coupled to a plunger configured to deliver fluid via the fluid path;

ceasing, by the control module, providing of the energy to the actuation arrangement after the actuation arrangement achieved the commanded actuation state;

subsequent to the actuation arrangement achieving the commanded actuation state, obtaining, by the control module, a measured actuation state of the actuation arrangement via a sensing arrangement, the measured actuation state being a state of the actuation arrangement in which the actuation arrangement moved in a direction reverse to a direction in which the actuation arrangement moved to achieve the commanded actuation state;

determining an acceleration of the actuation arrangement or the plunger for a drive cycle based at least in part on the measured actuation state; and

detecting, by the control module, an occlusion condition based on a difference between the determined acceleration and a reference acceleration for achieving the commanded actuation state and a relationship between the commanded actuation state and the measured actuation state.

2. The method of claim 1 , wherein detecting the occlusion condition comprises detecting the occlusion condition when a difference between the commanded actuation state and the measured actuation state is greater than an occlusion detection threshold.

3. The method of claim 1 , wherein:

operating the driver module comprises operating the driver module to provide current flow to the actuation arrangement to achieve the commanded actuation state for a first drive cycle;

obtaining the measured actuation state comprises obtaining the measured actuation state prior to operating the driver module for a subsequent drive cycle; and

determining the acceleration for the drive cycle comprises determining the acceleration for the subsequent drive cycle.

4. The method of claim 1 , wherein:

the actuation arrangement comprises a motor having a rotor coupled to the plunger;

the sensing arrangement comprises a rotor sensing arrangement;

the commanded actuation state comprises a commanded rotor position; and

the measured actuation state comprises a measured rotor position.

5. The method of claim 1 , further comprising:

identifying an initial resting actuation state via the sensing arrangement prior to providing a reference amount of input power to the actuation arrangement; and

determining the commanded actuation state based on the initial resting actuation state and the reference amount of input power, wherein:

operating the driver module comprises operating the driver module to provide the reference amount of input power to the actuation arrangement;

obtaining the measured actuation state of the actuation arrangement comprises obtaining the measured actuation state resulting from the reference amount of input power; and

detecting the occlusion condition comprises detecting the occlusion condition when a difference between the commanded actuation state and the measured actuation state is greater than an occlusion detection threshold.

6. The method of claim 5 , wherein:

the actuation arrangement comprises a motor having a rotor coupled to the plunger;

the sensing arrangement comprises a rotor sensing arrangement;

the commanded actuation state comprises an expected rotor position; and

the measured actuation state comprises a measured rotor position.

7. The method of claim 1 , the actuation arrangement comprising a motor having a rotor coupled to the plunger, the method further comprising determining an expected rotor position during operation of the driver module to provide the energy to the motor to achieve a commanded rotor position, wherein:

obtaining the measured actuation state comprises obtaining a measured rotor position via a rotor sensing arrangement; and

detecting the occlusion condition comprises detecting the occlusion condition when a difference between the expected rotor position and the measured rotor position is greater than an occlusion detection threshold.

8. The method of claim 7 , wherein determining the expected rotor position comprises determining the expected rotor position based on a commutation state for the motor.

9. An infusion device comprising:

an actuation arrangement coupled to a plunger to deliver fluid via a fluid path;

a driver module coupled to the actuation arrangement to selectively provide input power to the actuation arrangement;

a sensing arrangement to measure actuation of the actuation arrangement; and

a control module coupled to the driver module and the sensing arrangement to operate the driver module to:

provide the input power to the actuation arrangement to achieve a commanded actuation state;

cease providing of the input power to the actuation arrangement after the actuation arrangement achieved the commanded actuation state;

subsequent to the actuation arrangement achieving the commanded actuation state, obtain a measured actuation state of the actuation arrangement using the sensing arrangement, the measured actuation state being a state of the actuation arrangement in which the actuation arrangement moved in a direction reverse to a direction in which the actuation arrangement moved to achieve the commanded actuation state;

determine an acceleration of the actuation arrangement or the plunger for a drive cycle based at least in part on the measured actuation state; and

detect an anomalous condition based on a difference between the determined acceleration and a reference acceleration for achieving the commanded actuation state and a relationship between the commanded actuation state and the measured actuation state.

10. The infusion device of claim 9 , wherein:

the actuation arrangement comprises a motor having a rotor coupled to the plunger;

the sensing arrangement comprises a rotor sensing arrangement;

the commanded actuation state comprises a commanded rotor position; and

the measured actuation state comprises a measured rotor position.

11. The infusion device of claim 10 , wherein:

the anomalous condition comprises an occlusion condition with respect to the fluid path detected when a difference between the commanded rotor position and the measured rotor position is greater than an occlusion detection threshold.

12. The infusion device of claim 9 , wherein:

the input power is configured to achieve a test amount of actuation;

the control module identifies an initial resting actuation state via the sensing arrangement prior to operating the driver module to provide the input power and determines the commanded actuation state based on the initial resting actuation state and the test amount of actuation; and

the anomalous condition comprises an occlusion condition detected when a difference between the commanded actuation state and the measured actuation state is greater than an occlusion detection threshold.

13. The infusion device of claim 12 , wherein:

the actuation arrangement comprises a motor having a rotor coupled to the plunger;

the sensing arrangement comprises a rotor sensing arrangement;

the commanded actuation state comprises an expected rotor position; and

the measured actuation state comprises a measured rotor position.

14. The infusion device of claim 9 , wherein:

the actuation arrangement comprises a motor having a rotor coupled to the plunger;

the sensing arrangement comprises a rotor sensing arrangement;

the measured actuation state comprises a measured rotor position;

the commanded actuation state comprises a commanded rotor position; and

the control module determines an expected rotor position based on a commutation state for the motor during operation of the driver module to achieve the commanded rotor position and detects an occlusion condition with respect to the fluid path when a difference between the expected rotor position and the measured rotor position is greater than an occlusion detection threshold.

15. A method of detecting an occlusion in a fluid path associated with an infusion device, the infusion device including a motor having a rotor coupled to a plunger displaceable to deliver fluid via the fluid path, the method comprising:

operating, by a control module of the infusion device, a driver module to provide current flow to the motor to achieve a commanded rotation of the rotor;

ceasing, by the control module, providing of the current flow to the motor after the rotor achieved the commanded rotation;

subsequent to the rotor achieving the commanded rotation, obtaining, by the control module, a measured rotor position via a rotor sensing arrangement and an acceleration of the rotor for a drive cycle based at least in part on the measured rotor position, the measured rotor position being a state of the rotor in which the rotor moved in a direction reverse to a direction in which the rotor moved to achieve the commanded rotation;

detecting, by the control module, an occlusion condition based at least in part on the measured rotor position and a difference between the obtained acceleration and a reference acceleration for achieving the commanded rotation; and

initiating, by the control module, a remedial action in response to detecting the occlusion condition.

16. The method of claim 15 , further comprising determining, by the control module, an expected rotor position based at least in part on the commanded rotation, wherein detecting the occlusion condition comprises detecting the occlusion condition when a difference between the expected rotor position and the measured rotor position exceeds an occlusion detection threshold.