RF energy controller and method for electrosurgical medical devices

1. A control unit that is configured to control delivery of radio frequency (RF) energy to a medical device, the control unit comprising:

an input terminal configured to receive RF energy from an RF generator;

switching circuitry configured to switch between a closed state and an open state,

wherein when the switching circuitry is configured in the closed state, the switching circuitry is configured to permit a first portion of the RF energy received from an RF generator to be output by the control unit to a medical device; and

wherein when the switching circuitry is configured in the open state, the switching circuitry is configured to prevent the first portion of the RF energy from being output by the control unit to the medical device;

energy measurement circuitry configured to:

measure an amount of the first portion of the RF energy delivered to the medical device; and

switch the switching circuitry from the closed state to the open state when the amount of the first portion of the RF energy delivered to the medical device reaches a predetermined RF energy level; and

power supply circuitry configured to:

receive a second portion of the RF energy received from the RF generator;

generate one or more power supplies based on the second portion of the RF energy; and

supply the one or more power supplies to the energy measurement circuitry to power the energy measurement circuitry.

2. The control unit of claim 1 , further comprising an input connector configured to be coupled to an output of the RF generator and receive the RF energy from the output of the RF generator.

3. The control unit of claim 2 , wherein the input connector is configured to be removably attached to the output of the RF generator.

4. The control unit of claim 1 , wherein the control unit is configured to connect to a bipolar output of the RF generator.

5. The control unit of claim 1 , wherein the energy measurement circuitry comprises:

multiplier circuitry configured to:

multiply a first signal indicative of voltage delivered to the medical device with a second signal indicative of current delivered to the medical device, the multiplication being indicative of instantaneous power being delivered to the medical device.

6. The control unit of claim 5 , wherein the energy measurement circuitry further comprises integrator circuitry in communication with the multiplier circuitry, the integrator configured to:

receive a third signal indicative of the instantaneous power delivered to the medical device; and

integrate the third signal, the integration being indicative of an amount of the first portion of the RF energy delivered to the medical device.

7. The control unit of claim 6 , wherein the energy measurement circuitry further comprises: comparator circuitry in communication with the integrator circuitry, the comparator circuitry configured to:

receive a fourth signal indicative of the amount of the first portion of the RF energy delivered to the medical device; and

compare the fourth signal with a reference level to determine whether the amount of the first portion of the RF energy has reached a threshold energy level; and

upon determination that the amount of the first portion of the RF energy has reached the threshold energy level, generate a fifth signal that causes the switching circuitry to switch from the closed state to the open state.

8. The control unit of claim 1 , wherein the switching circuitry comprises a relay configured to switch from a closed state to an open state when the amount of the first portion of the RF energy delivered to the medical device reaches the predetermined RF energy level.

9. The control unit of claim 1 , wherein the switching circuitry further comprises a first switch connected in series with a second switch, wherein the first switch is configured to switch from a closed state to an open state when the amount of the first portion of the RF energy reaches the predetermined energy level, and wherein the second switch is configured to switch from the closed state to the open state in response to an elapsed predetermined period of time.

10. The control unit of claim 1 , wherein the control unit comprises a housing separate from and housing of the RF generator.

11. A method to control transmission of radio frequency (RF) energy from a RF generator to a medical device with a control unit coupled to the RF generator and the medical device, the method comprising:

configuring switching circuitry of the control unit in a closed state;

receiving, at an input of the control unit, the RF energy from the RF generator;

when the switching circuitry is in the closed state:

receiving, with the switching circuitry, a first portion of the RF energy; and

transmitting, with the switching circuitry, the first portion of the RF energy to an output of the control unit;

determining, with energy measurement circuitry, an amount of the first portion of the RF energy delivered to the medical device;

switching the switching circuitry, from the closed state to an open state in response to determining that the amount of the first portion of the RF energy reached a predetermined threshold energy level;

receiving, with power supply circuitry of the control unit, a second portion of the RF energy;

generating, with the power supply circuitry, one or more power supplies based on the second portion of the RF energy; and

supplying, with the power supply circuitry, the one or more power supplies to the energy measurement circuitry to power the energy measurement circuitry.

12. The method of claim 11 , further comprising:

coupling an input of the control unit to an output of the RF generator prior to a medical procedure being performed at a treatment site within a patient using the medical device; and

decoupling the input of the control unit from the output of the RF generator after the medical procedure is performed.

13. The method of claim 11 , further comprising:

generating, with step-down circuitry, a first signal indicative of voltage delivered to the medical device and a second signal indicative of current delivered to the medical device based on the first portion of the RF energy; and

wherein determining, with the energy measurement circuitry, the amount of the first portion of the RF energy delivered to the medical device comprises:

multiplying, with multiplier circuitry, the first signal and the second signal; the multiplication indicative of instantaneous power delivered to the medical device.

14. The method of claim 13 , wherein determining, with the energy measurement circuitry, the amount of the first portion of the RF energy delivered to the medical device further comprises:

integrating, with integrator circuitry, signals indicative of the instantaneous power that were generated from the multiplication by the multiplier circuitry, the integration indicative of the amount of the first portion of the RF energy delivered to the medical device.

15. The method of claim 14 , further comprising:

comparing, with comparator circuitry, a third signal indicative of the first amount of the first portion of the RF energy with a reference level, the third signal generated from the integration by the integrator circuitry, the reference level indicative of the predetermined threshold energy level; and

determining, with the comparator circuitry, that the third signal reached the reference level, the determination being based on the comparison,

wherein switching the switching circuitry from the closed state to the open state comprises switching the switching circuitry from the closed state to the open state upon determining with the comparator circuitry that the third signal reached the reference level.

16. A control unit configured to control delivery of radio frequency (RF) energy, the control unit comprising:

an output coupled to a medical device configured to perform an ablation procedure;

an input coupled to an output of a RF generator configured to supply RF energy to the medical device for the ablation procedure;

switching circuitry coupled to the input and the output, the switching circuitry configured to permit the control unit to output a first portion of the RF energy received from the RF generator in a closed state, and to prevent the control unit from outputting the first portion of the RF energy received from the RF generator in an open state; and

energy measurement circuitry coupled to the output, the energy measurement circuitry configured to determine an amount of the first portion of the RF energy being delivered to the medical device, and to switch the switching circuitry from the closed state to the open state when the amount of first portion of the RF energy reaches a threshold level; and

power supply circuitry configured to:

receive a second portion of the RF energy received from the RF generator;

generate one or more power supplies based on the second portion of the RF energy received from the RF generator; and

supply the one or more power supplies to active components of the control unit.

17. The control unit of claim 16 , wherein the control unit comprises a housing that is outside a housing of the RF generator when the input of the control unit is coupled to the output of the RF generator.

18. The control unit of claim 16 , wherein the energy measurement circuitry comprises:

analog multiplier circuitry configured to multiply signals indicative of voltage delivered to the medical device with signals indicative of current delivered to the medical device;

analog integrator circuitry configured to integrate signals generated from the multiplication, the integration indicative of the RF energy delivered to the medical unit.