Systems and methods for generating electrosurgical energy using a multistage power converter

• US 9,872,719 B2
• Filed: 02/13/2014
• Issued: 01/23/2018
• Est. Priority Date: 07/24/2013
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Covidien LP (Medtronic Plc)
• Inventors: Johnson, Joshua H.
• Primary Examiner(s): Della, Jaymi
• Assistant Examiner(s): Kim, Eunhwa
• Application Number:
  US14/179,724
• Publication Number:
  US 20150032096A1
• Time in Patent Office: 1,440 Days
• CPC Class Codes: A61B 18/1206 Generators therefor
• CPC Class Codes: A61B 2018/00666 using a threshold value
• CPC Class Codes: A61B 2018/00702 Power or energy
• CPC Class Codes: A61B 2018/0072 Current
• CPC Class Codes: A61B 2018/00767 Voltage
• CPC Class Codes: A61B 2018/00827 Current
• CPC Class Codes: A61B 2018/00875 Resistance or impedance
• CPC Class Codes: A61B 2018/00892 Voltage
• CPC Class Codes: A61B 2018/1286 having a specific transformer
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 3/156 with automatic control of output voltage or current, e.g. switching regulators
• CPC Class Codes: H02M 3/1584 with a plurality of power processing stages connected in parallel
• CPC Class Codes: H02M 7/06 using discharge tubes without control electrode or semiconductor devices without control electrode
• CPC Class Codes: H02M 7/4815 Resonant converters H02M7/4811 and H02M7/4826 take precedence
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

The electrosurgical systems and methods according to the present disclosure use a multi-stage power converter for generating electrosurgical energy. The electrosurgical systems include an electrosurgical generator having a power converter coupled to an electrical energy source and configured to generate electrosurgical energy. The power converter includes a boost converter configured to convert a first direct current from the electrical energy source to a second direct current, and a phase-shifted pulse width modulation (PS-PWM) resonant inverter configured to invert the second direct current to an alternating current. The electrosurgical generator also includes a plurality of sensors configured to sense a voltage and a current of the generated electrosurgical energy and a controller coupled to the power converter and the plurality of sensors. The controller includes a signal processor configured to determine tissue impedance based on the sensed voltage and current, and an output controller configured to select one of a plurality of output characteristics based on the determined tissue impedance, and to generate control signals to control the boost converter and the PS-PWM resonant inverter, according to the selected output characteristic.

Claims

1. An electrosurgical generator comprising:

a power converter coupled to an electrical energy source and configured to generate electrosurgical energy, the power converter including;

a boost converter configured to convert a first direct current from the electrical energy source to a second direct current; and

a phase-shifted pulse width modulation (PS-PWM) resonant inverter configured to invert the second direct current to an alternating current;

a plurality of sensors configured to sense voltage and current waveforms of the generated electrosurgical energy; and

a controller coupled to the power converter and the plurality of sensors, the controller comprising;

a signal processor configured to determine a tissue impedance based on the sensed voltage and current waveforms; and

an output controller configured to select one among a plurality of output characteristics based on the tissue impedance, and to generate a first control signal to control the boost converter and a second control signal to control the PS-PWM resonant inverter, according to the selected output characteristic,

wherein a switching frequency of the boost converter is greater than a switching frequency of the PS-PWM resonant inverter and the switching frequency of the boost converter is an integer multiple of the switching frequency of the PS-PWM resonant inverter,

wherein the plurality of output characteristics include a constant current output characteristic, a constant voltage output characteristic, and a constant power output characteristic,

wherein, when the output characteristic is the constant voltage output characteristic, the output controller generates the second control signal having a first fixed phase and a varying duty cycle, and

wherein, when the output characteristic is the constant power output characteristic, the output controller generates the second control signal having a second fixed phase, which is different from the first fixed phase, and a fixed duty cycle.

2. The electrosurgical generator according to claim 1, wherein the output controller shifts from the constant current output characteristic to the constant power output characteristic and from the constant power output characteristic to the constant voltage output characteristic based on the tissue impedance.

3. The electrosurgical generator according to claim 1, wherein the output controller selects the constant current output characteristic if the tissue impedance is less than a first predetermined value,

wherein the output controller selects the constant power output characteristic if the tissue impedance is greater than or equal to the first predetermined value and less than a second predetermined value,

wherein the output controller selects the constant voltage output characteristic if the tissue impedance is greater than or equal to the second predetermined value and less than a third predetermined value, and

wherein the first predetermined value is less than the second predetermined value and the second predetermined value is less than the third predetermined value.

4. The electrosurgical generator according to claim 1, wherein, when the output characteristic is the constant voltage output characteristic, the output controller generates the first control signal under a voltage control mode.

5. The electrosurgical generator according to claim 1, wherein, when the output characteristic is the constant current output characteristic, the output controller generates the first control signal under a voltage control mode and generates the second control signal having a third fixed phase.

6. The electrosurgical generator according to claim 1, wherein, when the output characteristic is the constant power output characteristic, the output controller generates the first control signal under a current programmed mode.

7. The electrosurgical generator according to claim 1, wherein, when the output characteristic is any one of the constant voltage output characteristic, the constant current output characteristic, and the constant power output characteristic, the output controller generates the first control signal under a current programmed mode.

8. The electrosurgical generator according to claim 1, wherein the boost converter includes a plurality of boost converters to lower ripples of the voltage and current input to the PS-PWM resonant inverter.

9. The electrosurgical generator according to claim 1, wherein the electrosurgical generator further comprises a plurality of analog-to-digital converters (ADCs) configured to sample the sensed voltage and the sensed current to obtain a predetermined number of samples of each of the sensed voltage and the sensed current, and

wherein the predetermined number of samples corresponds to an integer multiple of an RF frequency of the sensed voltage and the sensed current.

10. The electrosurgical generator according to claim 1, wherein the plurality of sensors includes a Rogowski coil.

11. The electrosurgical generator according to claim 1, wherein the controller is implemented in a field programmable gate array, an application specific integrated circuit, or a digital signal processor.

12. The electrosurgical generator according to claim 1, wherein the output controller is further configured to select one mode among a plurality of modes based on the output characteristics.

13. The electrosurgical generator according to claim 12, wherein the plurality of modes include a voltage control mode and a current programmed mode.

14. The electrosurgical generator according to claim 12, wherein the output controller generates the first control signal based on the selected mode to control the boost converter.