VARIABLE ACTIVE SNUBBER CIRCUIT TO INDUCE ZERO-VOLTAGE-SWITCHING IN A CURRENT-FED POWER CONVERTER

Abstract

An electrosurgical generator includes: a power supply configured to output a direct current; a current source coupled to the power supply and configured to output source current based on the direct current, and a power converter coupled to the current source, the power converter including at least one power switching element operated at a switching waveform. The power converter is configured to generate a converted waveform based on the source current. The electrosurgical generator also includes a controller coupled to the power converter and configured to modulate the switching waveform and a snubber circuit coupled to the current source and the power converter. The snubber circuit is configured to return the voltage at the at least one power switching element to zero after the power converter generates at least a portion of the converted waveform.

Claims

1. An electrosurgical generator, comprising: a power supply configured to output direct current; a current source coupled to the power supply and configured to output a source current based on the direct current; a power converter coupled to the current source, the power converter including at least one power switching element operated at a switching waveform, the power converter configured to generate a converted waveform based on the source current; a controller coupled to the power converter and configured to modulate the switching waveform; and a snubber circuit coupled to the current source and the power converter, the snubber circuit configured to return a voltage at the at least one power switching element to zero after the power converter generates at least a portion of the converted waveform.

2. The electrosurgical generator according to claim 1, wherein the power converter includes four power switching elements arranged in an H-bridge topology.

3. The electrosurgical generator according to claim 1, wherein the snubber circuit includes a snubber inductor, a snubber capacitor, and a snubber catch diode, all of which are interconnected in series.

4. The electrosurgical generator according to claim 3, wherein the snubber circuit further includes at least one snubber switching element coupling the snubber inductor to the snubber capacitor and the snubber catch diode.

5. The electrosurgical generator according to claim 4, wherein the snubber catch diode is configured to clamp a voltage at the snubber inductor and to charge the snubber capacitor in response to deactivation of the power converter.

6. The electrosurgical generator according to claim 4, wherein the controller is coupled to the snubber circuit and is configured to control the at least one snubber switching element to maintain a desired voltage in the snubber capacitor.

7. The electrosurgical generator according to claim 5, wherein the snubber inductor is configured to reverse a current therethrough after the snubber capacitor is charged to generate ring-back to counteract capacitance of the power converter.

8. An electrosurgical generator, comprising: a power supply configured to output direct current; a current source coupled to the power supply and configured to output source current based on the direct current; a power converter coupled to the current source, the power converter including four power switching elements arranged in an H-bridge topology and operated at a switching waveform, the power converter configured to generate a converted waveform based on the source current; a controller coupled to the power converter and configured to modulate the switching waveform; and a snubber circuit coupled to the current source and the power converter, the snubber circuit configured to return a voltage at each of the power switching elements to zero after the power converter generates at least a portion of the converted waveform.

9. The electrosurgical generator according to claim 8, wherein the snubber circuit includes a snubber inductor, a snubber capacitor, and a snubber catch diode, all of which are interconnected in series.

10. The electrosurgical generator according to claim 9, wherein the snubber circuit further includes at least one snubber switching element coupling the snubber inductor with the snubber capacitor and the snubber catch diode.

11. The electrosurgical generator according to claim 10, wherein the snubber catch diode is configured to clamp a voltage at the snubber inductor and to charge the snubber capacitor in response to deactivation of the power converter.

12. The electrosurgical generator according to claim 10, wherein the controller is coupled to the snubber circuit and is configured to control the at least one snubber switching element to maintain a desired voltage in the snubber capacitor.

13. The electrosurgical generator according to claim 12, wherein the snubber inductor is configured to reverse a current therethrough after the snubber capacitor is charged to generate ring-back to counteract capacitance of the power converter.

14. A method for controlling an electrosurgical generator, the method comprising: activating a first pair of power switching elements and a second pair of power switching elements of a power converter; increasing current at a current source coupled to the power converter; deactivating the first pair of the power switching elements to generate a radio frequency pulse; deactivating at least one power switching element of the second pair of the power switching elements; and activating a snubber circuit coupled to the current source and the power converter to return voltage at each of the power switching elements to zero prior to reactivating the first pair of power switching elements and the second pair of power switching elements.

15. The method according to claim 14, wherein activating the snubber circuit includes: increasing voltage at a snubber inductor of the snubber circuit.

16. The method according to claim 15, wherein activating the snubber circuit further includes clamping current at the snubber inductor by a snubber catch diode of the snubber circuit in response to deactivating the at least one power switching element of the second pair of the power switching elements.

17. The method according to claim 16, wherein activating the snubber circuit further includes charging a snubber capacitor of the snubber circuit.

18. The method according to claim 17, wherein activating the snubber circuit further includes controlling at least one snubber switching element of the snubber circuit to maintain a desired voltage in the snubber capacitor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present disclosure may be understood by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description, in which:

[0020] FIG. 1 is a perspective view of a surgical system according to an embodiment of the present disclosure;

[0021] FIG. 2 is a front view of an electrosurgical generator of FIG. 1 according to an embodiment of the present disclosure;

[0022] FIG. 3 is a schematic diagram of the electrosurgical generator of FIG. 2 according to an embodiment of the present disclosure;

[0023] FIG. 4 is a schematic diagram of a variable active snubber circuit of the electrosurgical generator of FIG. 2 according to the present disclosure;

[0024] FIG. 5 is a plot of a switching waveform, a generator output waveform, a power converter waveform, and a current source waveform according to the present disclosure; and

[0025] FIG. 6 is a flow chart of a method for operating the electrosurgical generator of FIG. 2 according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0026] Particular embodiments of the present disclosure will be described below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail. Those skilled in the art will understand that the present disclosure may be adapted for use with either an endoscopic instrument, a laparoscopic instrument, or an open instrument. It should also be appreciated that different electrical and mechanical connections and other considerations may apply to each particular type of instrument.

[0027] A generator may be used in monopolar and/or bipolar electrosurgical procedures, including, for example, cutting, coagulation, ablation, and vessel sealing procedures. The generator may include a plurality of outputs for interfacing with various ultrasonic and electrosurgical instruments (e.g., ultrasonic dissectors and hemostats, monopolar instruments, return electrode pads, bipolar electrosurgical forceps, footswitches, etc.). Further, the generator may include electronic circuitry configured to generate radio frequency energy specifically suited for powering ultrasonic instruments and electrosurgical devices operating in various electrosurgical modes (e.g., cut, blend, coagulate, division with hemostasis, fulgurate, spray, etc.) and procedures (e.g., monopolar, bipolar, vessel sealing).

[0028] FIG. 1 is a perspective view of the components of one illustrative embodiment of an electrosurgical system 10 according to the present disclosure. The system 10 may include one or more monopolar electrosurgical instruments 20 having one or more active electrodes 23 (e.g., electrosurgical cutting probe, ablation electrode(s), etc.) for treating tissue of a patient. Electrosurgical alternating RF current is supplied to the instrument 20 by a generator 200 via a supply line 24 that is connected to an active terminal 230 (FIG. 3) of the generator 200, allowing the instrument 20 to cut, coagulate, thermally or non-thermally ablate and/or otherwise treat tissue. The alternating current is returned to the generator 200 through a return electrode pad 26 via a return line 28 at a return terminal 232 (FIG. 3) of the generator 200. For monopolar operation, the system 10 may include a plurality of return electrode pads 26 that, in use, are disposed on a patient to minimize the chances of tissue damage by maximizing the overall contact area with the patient. In addition, the generator 200 and the return electrode pads 26 may be configured for monitoring tissue-to-patient contact to ensure that sufficient contact exists therebetween.

[0029] The system 10 may also include one or more bipolar electrosurgical instruments, for example, a bipolar electrosurgical forceps 30 having one or more electrodes for treating tissue of a patient. The electrosurgical forceps 30 includes a housing 31 and opposing jaw members 33 and 35 disposed at a distal end of a shaft 32. The jaw members 33 and 35 have one or more active electrodes 34 and a return electrode 36 disposed therein, respectively. The active electrode 34 and the return electrode 36 are connected to the generator 200 through cable 38 that includes the supply and return lines 24, 28, which may be coupled to the active and return terminals 230, 232, respectively (FIG. 3). The electrosurgical forceps 30 is coupled to the generator 200 at a port having connections to the active and return terminals 230 and 232 (e.g., pins) via a plug disposed at the end of the cable 38, wherein the plug includes contacts from the supply and return lines 24, 28 as described in more detail below.

[0030] With reference to FIG. 2, a front face 240 of the generator 200 is shown. The generator 200 may include a plurality of ports 250-262 to accommodate various types of electrosurgical instruments (e.g., monopolar electrosurgical instrument 20, electrosurgical forceps 30, etc.).

[0031] The generator 200 includes a user interface 241 having one or more display screens 242, 244, 246 for providing the user with variety of output information (e.g., intensity settings, treatment complete indicators, etc.). Each of the screens 242, 244, 246 is associated with a corresponding port 250-262. The generator 200 includes suitable input controls (e.g., buttons, activators, switches, touch screen, etc.) for controlling the generator 200. The screens 242, 244, 246 are also configured as touch screens that display a corresponding menu for the instruments (e.g., electrosurgical forceps 30, etc.). The user then adjusts inputs by simply touching corresponding menu options.

[0032] Screen 242 controls monopolar output and the devices connected to the ports 250 and 252. Port 250 is configured to couple to a monopolar electrosurgical instrument (e.g., electrosurgical instrument 20) and port 252 is configured to couple to a foot switch (not shown). The foot switch provides for additional inputs (e.g., replicating inputs of the generator 200). Screen 244 controls monopolar and bipolar output and the devices connected to the ports 256 and 258. Port 256 is configured to couple to other monopolar instruments. Port 258 is configured to couple to a bipolar instrument (not shown).

[0033] Screen 246 controls the electrosurgical forceps 30 that may be plugged into one of the ports 260 and 262, respectively. The generator 200 outputs energy through the ports 260 and 262 suitable for sealing tissue grasped by the electrosurgical forceps 30. In particular, screen 246 outputs a user interface that allows the user to input a user-defined intensity setting for each of the ports 260 and 262. The user-defined setting may be any setting that allows the user to adjust one or more energy delivery parameters, such as power, current, voltage, energy, etc. or sealing parameters, such as energy rate limiters, sealing duration, etc. The user-defined setting is transmitted to a controller 224 (FIG. 3) where the setting may be saved in memory. In embodiments, the intensity setting may be a number scale, such as for example, from one to ten or one to five. In embodiments, the intensity setting may be associated with an output curve of the generator 200. The intensity settings may be specific for each electrosurgical forceps 30 being utilized, such that various instruments provide the user with a specific intensity scale corresponding to the electrosurgical forceps 30. The active and return terminals 230 and 232 may be coupled to any of the desired ports 250-262. In embodiments, the active and return terminals 230 and 232 may be coupled to the ports 250-262.

[0034] FIG. 3 shows a schematic block diagram of the generator 200, which includes a controller 224, a power supply 227, and a power converter 228. The power supply 227 may be a high voltage, DC power supply connected to an AC source (e.g., line voltage) and provides high voltage, DC power to the power converter 228, which then converts high voltage, DC power into RF energy and delivers the energy to the active terminal 230. The energy is returned thereto via the return terminal 232. In particular, electrosurgical energy for energizing the monopolar electrosurgical instrument 20 and/or electrosurgical forceps 30 is delivered through the active and return terminals 230 and 232. The active and return terminals 230 and 232 may be coupled to the power converter 228 through an isolation transformer 229. The isolation transformer 229 is optional and the active and return terminals 230 and 232 may be coupled directly to converter 228.

[0035] The generator 200 also includes a DC-DC buck converter 234 coupled to the power supply 227. Furthermore, a current source 236 is electrically coupled to the DC-DC buck converter 234 and the power converter 228. The current source 236 may be an inductor having an inductance which smoothes the current supplied to the power converter 228. The current source 236 is configured to supply current to the power converter 228. The output of power converter 228 transmits current through an isolation transformer 229 to the load “Z”, e.g., tissue being treated.

[0036] The power converter 228 is configured to operate in a plurality of modes, during which the generator 200 outputs corresponding waveforms having specific duty cycles, peak voltages, crest factors, etc. It is envisioned that in other embodiments, the generator 200 may be based on other types of suitable power supply topologies. Power converter 228 may be a resonant RF amplifier or a non-resonant RF amplifier. A non-resonant RF amplifier, as used herein, denotes an amplifier lacking any tuning components, e.g., conductors, capacitors, etc., disposed between the power converter and the load “Z.”

[0037] The controller 224 includes a processor (not shown) operably connected to a memory (not shown), which may include one or more of volatile, non-volatile, magnetic, optical, or electrical media, such as read-only memory (ROM), random access memory (RAM), electrically-erasable programmable ROM (EEPROM), non-volatile RAM (NVRAM), or flash memory. The processor may be any suitable processor (e.g., control circuit) adapted to perform the operations, calculations, and/or set of instructions described in the present disclosure including, but not limited to, a hardware processor, a field programmable gate array (FPGA), a digital signal processor (DSP), a central processing unit (CPU), a microprocessor, and combinations thereof. Those skilled in the art will appreciate that the processor may be substituted for by using any logic processor (e.g., control circuit) adapted to perform the calculations and/or set of instructions described herein.

[0038] The controller 224 includes an output port that is operably connected to the power supply 227 and/or power converter 228 allowing the processor to control the output of the generator 200 according to either open and/or closed control loop schemes. A closed loop control scheme is a feedback control loop, in which a plurality of sensors measure a variety of tissue and energy properties (e.g., tissue impedance, tissue temperature, output power, current and/or voltage, etc.), and provide feedback to the controller 224. The controller 224 then controls the power supply 227 and/or power converter 228, which adjusts the DC and/or power supply, respectively.

[0039] The generator 200 according to the present disclosure may also include a plurality of sensors (not shown). The sensors may be coupled to the power supply 227, the current source 234, and/or power converter 228 and may be configured to sense properties of DC current supplied to the power converter 228 and/or RF energy outputted by the power converter 228, respectively. Various components of the generator 200, namely, the power converter 228, the current and voltage sensors, may be disposed on a printed circuit board (PCB). The controller 224 also receives input signals from the input controls of the generator 200, the instrument 20 and/or electrosurgical forceps 30. The controller 224 utilizes the input signals to adjust power outputted by the generator 200 and/or performs other control functions thereon.

[0040] The DC-DC buck converter 234 includes a switching element 234a and power converter 228 includes a plurality of switching elements 228a-228d arranged in an H-bridge topology. In embodiments, power converter 228 may be configured according to any suitable topology including, but not limited to, half-bridge, full-bridge, push-pull, and the like. Suitable switching elements include voltage-controlled devices such as transistors, field-effect transistors (FETs), combinations thereof, and the like.

[0041] The controller 224 is in communication with both DC-DC buck converter 234 and power converter 228, in particular, the switching elements 234a and 228a-228d, respectively. Controller 224 is configured to output control signals, which may be a pulse-width modulated signal, to switching elements 234a and 228a-228d as described in further detail in co-pending application published as US 2014/0254221, filed on Dec. 4, 2013 by Johnson et al., the entire contents of which are incorporated by reference herein. In particular, controller 224 is configured to modulate a control signal d.sub.1 supplied to switching element 234a of DC-DC buck converter 234 and control signals d.sub.2 supplied to switching elements 228a-228d of power converter 228. Additionally, controller 224 is configured to measure power characteristics of generator 200, and control generator 200 based at least in part on the measured power characteristics. Examples of the measured power characteristics include the current through inductor 103 and the voltage at the output of power converter 228.

[0042] With reference to FIG. 4, the power converter 228 of the generator 200 is shown as a current-source power converter, which achieves zero-voltage-switching using a variable active snubber circuit 300. The snubber circuit 300 is coupled in parallel with the current source 236. The snubber circuit 300 includes a first node 301a disposed between the power supply 227 and the current source 236 and a second node 301b coupled to the power converter 228. The snubber circuit 300 includes a snubber inductor 302, a first switching element 304a, and a second switching element 304b. The first switching element 304a is connected to a ground and the second switching element 304b is connected in series with the power converter 228. The snubber circuit 300 also includes a snubber capacitor 306 and a snubber catch diode 308. The first and second switching elements 304a and 304b are configured to be switched at a fixed duty cycle by the controller 204 to establish the desired voltage at the snubber capacitor 306. The voltage in the snubber capacitor 306 is constantly being controlled via the first and second switching elements 304a and 304b and the snubber inductor 302 to maintain the desired capacitor voltage, which produces the desired ring-back at the second node 301b as described in more detail below.

[0043] Although FIG. 4 does not show the DC-DC buck converter 234, the snubber circuit 300 may be implemented with the DC-DC buck converter 234. In which case, the first node 301a would return to the DC-DC buck converter 234 rather than the power supply 227 as shown in FIG. 4.

[0044] FIG. 5 illustrates a plurality of waveforms, namely, a switching waveform 500 for switching the switching elements 228a-228d, a waveform 502 generated by the current source 236, a converted waveform 504 generated by the power converter 228, and an RF waveform 506 at the load “Z.” A method for operating the generator 200, and in particular the snubber circuit 300, is shown as a flow chart 600 in FIG. 6 and is described below with reference to FIG. 5.

[0045] Initially, during period 510 as shown in FIG. 5, all of the switching elements are turned on by the switching waveform 500 and current in the current source 236 ramps up to a desired predetermined level. Once the desired current is achieved, which may be determined by sensors (not shown) coupled to the controller 224, or by timing of the ramp time, one pair of the switching elements 228a-228d, e.g., switching element 228a and 228d or 228b and 228c, are turned off. This generates a first RF pulse (e.g., positive half cycles) that is supplied to the load “Z” during period 512.

[0046] At a predetermined time, during period 514, one of the high side switching elements, namely, switching element 228a or 228b, of the pair of the switching elements 228a and 228d or 228b and 228c, is also tuned off. As a result, all but one of the switching elements 228a-228d is turned off, namely, one of the low side switching elements 228c or 228d remains on. In embodiments, all of the remaining activated switching elements may also be turned off. In response to turning off the switching elements 228a-228d, the voltage at the output of the snubber inductor 302 rises very rapidly and is clamped by the snubber catch diode 308, which then feeds the energy into the snubber capacitor 306. In further embodiments, the power supply 227 feeding the current source 236 may also be turned off depending on specific requirements of downstream elements.

[0047] Due to the higher voltage at the snubber inductor 302, the energy in the snubber inductor 302 quickly dissipates and the current in the snubber inductor 302 reverses, causing ring-back due to the intended and incidental stray capacitance of the H-bridge circuitry of the power converter 208. In particular, the current from the snubber inductor 302 of the snubber 300 counteracts stray capacitance of the power converter 208. As the ring-back occurs, the voltage at the power converter 208 returns to zero.

[0048] During period 516, all of the switching element 228a-228d turn on to start the next cycle, which results in a reverse RF pulse (e.g., the negative half of the waveform 506 as compared to the pulse generated previously during period 512). The application of switching waveform 500 is repeated indefinitely to generate the desired waveform 506. In this implementation all forward or downstream current paths are turned off at the same time. As described above, this would be a catastrophic state for a conventional current-fed power supply were it not for the snubber circuit 300 according to the present disclosure.

[0049] While several embodiments of the disclosure have been shown in the drawings and/or described herein, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope of the claims appended hereto.