Apparatus and method for automatic catheter threader

Abstract

A system for the automated threading of catheters with cables, wires or fluid conductors during their manufacture is presented. The system provides for a vacuum catheter sheath clamping and enlarging mechanism that facilitates the treading of catheters within very tight confines. The system also provides for rotating needle and or conductor pushing and pulling mechanisms to allow the rapid threading of the catheters with carefully controlled parameters. These pushing and pulling mechanisms are monitored through force, torque, and position sensors so that materials are not damaged during manufacture.

1 . An apparatus for the automated threading of a catheter, comprising: 
 a) A clamping and enlarging means;    b) A needle or conductor pusher and puller assembly having a plurality of electric motors, a plurality of rollers connected to said motors, a plurality of sensors to ascertain the progress of the manufacturing step, and opening and closing means for gripping of materials;    c) a plurality of opening and closing means for gripping threading needles or conductors within said rollers;    d) a camera disposed to overlook the workspace;    e) an image processor means;    f) a plurality of electric motor controllers;    g) an industrial computer, wherein said image processor means feeds the visual information captured by said camera to the industrial computer to monitor the progress of the manufacturing step and wherein said computer schedules movement of the different parts of the apparatus through the plurality of motor controlling means; and    h) A computer based controller with stored program means to control the entire apparatus assembly and the sequence of operations.    
   
   
       2 . The apparatus for the threading of catheters of  claim 1 , wherein said sensors comprise: 
 a) position sensors to detect the position of the threading needle and or conductors entering and emerging from the sheath to be threaded;    b) a sensor to measure the gap between the slider plates.    
   
   
       3 . The apparatus for the threading of catheters of  claim 1 , said pusher and puller assembly further comprising: 
 a) a slider stage having a base provided with a two section screw and being driven by a motor having control wires; wherein one half of said two section screw is right handed and the other half of said two section screw is left handed;    b) a plurality of slider plates said two section screw being connected to said slider plates such that when the screw turns in one direction the slider plates are drawn apart, and when the screw turns in the opposite direction the slider plates come together;    c) a plurality of L-shaped brackets fixedly connected to the slider plates;    d) Force plates having sensor wires and being affixed to the L-shaped brackets;    e) A C-shaped bracket attached to each of the L-shaped brackets so that the assembly may slide relative to the L-shaped brackets and transmit any forces applied to the force placed in between the L and C-shaped brackets;    f) Controllable motors having control wires and being mounted on each of the C-shaped brackets;    g) A rotary encoder and a torque sensor to monitor the operation so that if high torque is measured with no movement this indicates an obstruction and proper action must be taken;    h) A plurality of rubberized wheels in contact with the needle and tubing making it advance or retract;    i) A plurality of shafts for sustaining the vertical rotating assemblies;    j) Stiffening brackets for maintaining the rotary encoder and torque sensor in position;    
   
   
       4 . The apparatus for the threading of catheters of  claim 1 , wherein said clamping and enlarging means is supplied with vacuum means for straightening and facilitating the threading of cables, wires, or fluid conductors through the catheter sheath.  
   
   
       5 . The apparatus for the threading of catheters of  claim 4 , wherein: 
 a) said clampling and enlarging means is a hinged vacuum clamp, having a lower part, and upper part, a distal end, and a proximal end; said distal end and said proximal end each having a protrusion through which a needle may be inserted;    b) said vacuum clamp is disposed so as to be able to encase and enlarge a catheter sheath device.    
   
   
       6 . A method of using the apparatus for the threading of catheter of  claim 1 , comprising the steps of: 
 a) Clamping and enlarging the catheter sheath with the vacuum clamping means;    b) Passing a threading needle through the sheath by using the pusher and puller assembly;    c) Monitoring the pushing torque, rotational movement, and pinching forces with a supervisory and control microcomputer;    d) Monitoring the status of the manufacturing step with said supervisory and control computer and making decisions based on the information gathered by the sensors.    
   
   
       7 . A clamp device for clamping and enlarging a catheter sheath, comprising: 
 a) A hinged clamp having a lower part, an upper part, a distal end, and a proximal end; said distal end and said proximal end each having a protrusion through which a needle may be inserted said clamp having vacuum means for straightening and facilitating the threading of cables, wires, or fluid conductors through the catheter sheath a hinged vacuum clamp; and    b) said clamp being disposed so as to be able to encase and enlarge a catheter sheath device.    
   
   
       8 . The clamp device of  claim 7 , wherein said vacuum clamp includes connected striations visible in both the lower part and the upper part.