Systems and methods for surgical system battery management

Abstract

A surgical system is provided that includes battery packs, a power subsystem, and a controller. The power subsystem is configured to connect at least two battery packs in parallel during a backup mode, disconnect the battery packs in a non-backup mode, and prevent each battery pack from charging one or more other battery packs during parallel operation. The controller is configured to individually charge each battery pack to a power capacity that is equal to or less than a predetermined power capacity, such as 100 Wh.

Description

Cross-references to related applications

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 594,918 (filed October 31, 2023), the contents of which are incorporated herein by reference in their entirety. Background Technology

[0002] Cataract surgery involves removing the cataract lens and replacing it with an artificial intraocular lens (IOL). Cataract lens removal is typically achieved by fracturing the lens and aspirating the fragments out of the eye. This fracturing can be done using, for example, a phacoemulsification probe, a laser probe, or another suitable instrument. During the procedure, the probe fractures the lens, and the fragments are aspirated out of the eye through, for example, a hollow needle or cannula. Throughout the procedure, irrigation fluid is pumped into the eye to maintain intraocular pressure (IOP) and prevent eye collapse.

[0003] However, AC (alternating current) power failures can occur during cataract surgery. Such AC power failures can harm patients undergoing cataract surgery. However, conventional surgical consoles have several significant drawbacks, including the inability to maintain a stable power supply connection to the surgical console. Summary of the Invention

[0004] Embodiments of this disclosure provide a surgical system including multiple battery packs, a power subsystem, and a controller. The power subsystem is configured to connect at least two battery packs in parallel during standby mode, disconnect these battery packs in non-standby mode, and prevent each battery pack from charging one or more other battery packs during parallel operation. The controller is configured to individually charge each battery pack to a power capacity equal to or less than a predetermined power capacity (e.g., 100 Wh). Attached Figure Description

[0005] To gain a detailed understanding of the features described above, reference can be made to the embodiments to provide a more specific description of the disclosure, some of which are illustrated in the accompanying drawings. However, it should be noted that the drawings only illustrate some aspects of this disclosure, and that other equally effective embodiments are permissible.

[0006] Figure 1A An exemplary ophthalmic surgical system according to certain embodiments is shown.

[0007] Figure 1B Depicting according to certain embodiments Figure 1A and Figure 1B A system block diagram of an exemplary ophthalmic surgical system.

[0008] Figure 2 Depicting according to certain embodiments Figure 1A and Figure 1B Another system block diagram of an exemplary ophthalmic surgical system.

[0009] Figure 3 A flowchart for charging a battery pack according to certain embodiments is depicted.

[0010] For ease of understanding, the same reference numerals have been used where possible to refer to the same elements common to the figures. It is contemplated that elements and features of one embodiment can be advantageously combined in other embodiments without further description. Detailed Implementation

[0011] This disclosure will now be described in detail with reference to the accompanying drawings, which are provided as illustrative examples to enable those skilled in the art to practice this disclosure. It is important to note that the drawings and the examples below are not intended to limit the scope of this disclosure to a single embodiment, but other embodiments are possible by interchange of some or all of the elements described or shown. Furthermore, where certain elements of this disclosure can be implemented partially or entirely using known components, only those portions of such known components necessary for understanding this disclosure will be described, and detailed descriptions of other portions of such known components will be omitted so as not to obscure the disclosure.

[0012] This disclosure generally relates to ophthalmic surgical consoles, their components, and methods of using these consoles during certain ophthalmic surgical procedures. The evolution of medical and surgical techniques has led to a significant increase in power requirements to facilitate more efficient procedures. In the field of surgical console systems, there is a lack of power systems for power budget delivery that could benefit surgical console systems, where a power budget system can deliver, for example, 625 W (watts) of peak power for a duration of 2 seconds and provide 5.5 minutes of backup time (other power budget system capacities may also be used).

[0013] To meet the power delivery requirements of the surgical console system, a 175 Wh capacity (or other battery pack capacity) within a rechargeable battery pack (hereinafter "battery pack") can be used. However, the practicality of using a single 175 Wh battery pack is challenged, for example, due to limitations imposed by current air transport regulations (which limit the power capacity of a single handheld battery pack to no more than 100 Wh). This constraint is particularly evident during field installations where engineers need to manually carry these components. To circumvent such issues, the embodiments described herein utilize a power delivery system with two battery packs, each with a power capacity less than or equal to a predetermined power capacity, such as 100 Wh. This dual-battery pack architecture not only complies with current air transport regulations but also meets the system's power requirements by efficiently utilizing the current from both units through parallel connection of the two battery packs. Furthermore, the embodiments described herein can be used with battery packs of other sizes.

[0014] Importantly, while current air transport regulations may limit the power capacity of a single handheld battery pack to no more than 100 Wh, these regulations may become more lenient in the future, allowing for a power capacity exceeding 100 Wh. Therefore, predetermined power capacities can be increased to match new air transport regulations regarding power capacity, such as 120 Wh, 150 Wh, 200 Wh, etc.

[0015] In some embodiments, in addition to integrating two battery packs, a power management controller may be implemented to manage and balance the power load between the two battery packs. For example, the power controller may implement a method that includes charging one lithium-ion battery pack at a constant current at a time, and then switching to charging the second battery pack. In doing so, before starting to charge the second battery pack, the power controller ensures that the state of charge (SoC) between the battery packs remains within, for example, a 5% difference. This power charging protocol ensures that the two battery packs are charged equally within, for example, a 5% SoC range and are balanced to meet the system's power requirements. Other SoC ranges (e.g., 1%, 3%, 7%, 10%, 15%, etc.) can also be used.

[0016] In some embodiments, to extend battery pack life, the power management controller is configured to charge each battery pack only until it reaches a predetermined SoC limit (e.g., 80%) (other upper limits may also be used). While 80% is frequently used throughout as an example predetermined SoC limit, the predetermined SoC limit can be, for example, 50%, 60%, 70%, 75%, 85%, 90%, 95%, etc. In some embodiments, the predetermined state of charge can be predetermined by the user, predetermined during the manufacture of the surgical console, etc. The power management controller monitors and manages the upper limit of the SoC by charging or discharging the battery packs during the charging protocol, thereby effectively maintaining the SoC within, for example, a set range of 5%. Advantageously, the power management controller is not limited to managing only two battery packs. The embodiments described herein can be extended to manage any number of lithium-ion battery packs. This scalability makes the embodiments described herein highly suitable for meeting the high power backup requirements of future surgical products that employ the power delivery framework described herein to improve power solutions in ophthalmic surgical console systems.

[0017] Now for reference Figure 1A and Figure 1B , Figure 1A An ophthalmic surgery console system 10, which can be used to perform ophthalmic surgery on the eye according to certain embodiments, is shown. In the illustrated embodiments, the ophthalmic surgery console system 10 is interchangeably referred to as "console 100". Figure 1B A system block diagram corresponding to console 100 is depicted. As shown, console 100 includes an interface device 107 (e.g., a foot pedal) and a handheld device 112. Console 100 includes a housing 102 and a display screen 104, the housing housing housing a power management controller 103, an interface subsystem 106, a power subsystem 110, and a surgical tool subsystem 116 that communicate with the display screen 104.

[0018] One of the major challenges for ophthalmic surgical console systems is meeting the system's power budget, which can, for example, operate at 625 W peak power for 2 seconds with a 5.5-minute standby time. This power budget requirement can be met using a battery pack with a capacity of 175 Wh (or greater). However, current air transport regulations present logistical challenges for configurations utilizing a single 175 Wh battery pack. These regulations limit the power capacity of handheld battery packs to 100 Wh, creating problems for field installation, where these components must be transported by engineers.

[0019] Therefore, embodiments of this document provide a power delivery framework for surgical console systems employing two or more battery packs, each with a power capacity less than or equal to, for example, 100 Wh. This approach complies with current air transport regulations while meeting the system's power requirements by connecting the battery packs in parallel. As mentioned above, the power capacity of each battery pack can be increased accordingly when current air transport regulations are relaxed.

[0020] Advantageously, the embodiments described herein effectively utilize current from multiple battery packs and leverage a reliable and efficient power management controller 103 (or simply "controller 103" below) to balance the load on such battery packs. The controller 103 of the embodiments herein advantageously ensures equal charging among the battery packs while limiting the SoC (System of Charge) to extend battery life. The controller 103 facilitates efficient charging of the individual battery packs while maintaining load balance. The controller 103 is configured to charge one battery pack 109 at a time, thereby ensuring that the SoC among the battery packs 109a is within, for example, 5% (or, for example, 1%, 2%, 3%, 8%, 10%, etc.) before charging of the second battery pack 109b is initiated. The controller 103 can also limit the charging process to, for example, 80% SoC (or, for example, 70%, 75%, 85%, 90%, 95%, etc.) to extend battery life, which will be described in further detail below. Furthermore, the controller 103 is scalable and can be extended to any number of battery packs 109, such as battery packs 109a, 109b, ..., 109n.

[0021] In the embodiments described herein, battery pack 109 can advantageously play a significant role in ensuring compliance with transport regulatory capacity constraints arising from current air transport regulations. It is well known that the aviation industry has established guidelines for the transport of lithium batteries. A key concern is the power capacity of the battery pack. Current air transport regulations require that the capacity of any handheld battery pack not exceed 100 Wh. This limitation stems from safety considerations, as larger batteries could pose a more serious hazard in the event of failure or damage.

[0022] Considering these constraints, battery packs 109 can be designed to each have a power capacity of less than or equal to 100 Wh. This power capacity ensures compliance with current air transport regulations, making battery packs 109 safe and easy to transport by field engineers or any personnel requiring equipment relocation. While the individual capacity of each battery pack can be limited to 100 Wh, when connected in parallel, battery packs 109 can provide the combined power required to meet the requirements of the surgical console system without violating transport regulations. In some embodiments, to further facilitate transport and ensure safety, each battery pack 109 can be ergonomically designed and constructed to be compact and lightweight, making it easy to hold and carry without causing fatigue. Each battery pack 109 includes a high energy density, allowing it to store a large amount of energy despite its small size and light weight, which is advantageous for devices such as surgical console systems requiring reliable power (e.g., System 10).

[0023] Power delivery from each battery pack 109 is optimized to provide constant energy. When connected in parallel, system 10 can draw current evenly from multiple battery packs, ensuring efficient and balanced power distribution to meet peak power requirements. In some embodiments, each battery pack is equipped with an advanced charging controller. This controller ensures that the batteries are charged to their optimal capacity (e.g., up to 80% SoC) to extend lifespan and maintain health. Other optimal capacities (e.g., up to 70%, 75%, 85%, 90%, 95%, etc.) are also envisioned.

[0024] According to aviation safety standards, battery packs can incorporate safety features such as overcharge protection, over-discharge protection, short-circuit protection, and thermal protection. These features prevent any potential hazards that may arise from battery failure. While other battery types can be implemented, lithium-ion battery packs are particularly well-suited for medical applications due to the numerous advantages offered by their battery chemistry. For example, lithium-ion batteries are known for their high energy density, low self-discharge, and long cycle life, making them ideal for demanding applications.

[0025] Each battery pack 109 can be designed to have an extended operating life facilitated by a power management protocol of controller 103. For example, by limiting charging to a predetermined SoC (e.g., 80% SoC), losses on individual battery cells in battery pack 109 are significantly reduced, ensuring that battery pack replacement is not required for a much longer period of time. One of the advantageous features of battery pack 109 is its modular design, which allows for easy replacement or addition of battery packs as needed, making system 10 adaptable and scalable. More battery packs can be seamlessly integrated depending on specific power requirements. Furthermore, understanding the need for uninterrupted power (especially in critical applications), battery pack 109 can be designed for rapid battery swapping. This swapping feature allows for the rapid replacement of depleted batteries without shutting down the system.

[0026] Now for reference Figure 2 , combined Figure 1A and Figure 1B , Figure 2 Another system block diagram of an ophthalmic surgical system 10 according to one or more embodiments is depicted. As shown, a controller 103 communicates with certain components of a power subsystem 110 and together controls and operates the system 10. In some embodiments, the power subsystem 110 provides clean, stable, and sufficient power to components of the console 100 (such as the surgical tool subsystem 116, etc.) for reliable operation of the surgical console under varying AC device and environmental conditions (e.g., conditions expected in a global hospital environment).

[0027] like Figure 2 As shown, the surgical console 100 implements a modular architecture, wherein the power of each module is provided by, for example, a single main 24 VDC (direct current bus voltage) bus 201 distributed throughout the system 10. In some embodiments, the power subsystem 110 includes, in particular, an AC power input module 205, a standby switch 207, a battery pack 209 (e.g., battery packs 109a, 109b), and power distribution implemented through several PCBAs (printed circuit board assemblies).

[0028] In some embodiments, the power subsystem 110 receives rated input power from AC mains power (e.g., 100 VAC to 240 VAC, 50 / 60 Hz, etc.). Other input power from AC mains power may also be used / received (e.g., depending on the grid configuration / region where the power system 110 is located). The power subsystem 110 can deliver continuous power up to, for example, 918 W at +24 VDC under all or almost all operating conditions. Other power metrics are also envisioned.

[0029] For example, in the event of an AC mains power failure, battery pack 209 delivers the power required to maintain the operation of the surgical console for a selected period of time (e.g., in some embodiments, continuous power of at least 625 W can support normal system function for at least 1.5 seconds). (Other battery pack sizes and time periods are also envisioned (e.g., systems with different size / power requirements)). In some embodiments, power subsystem 110 may accept input from standby switch 207 and then drive the backlight of standby switch 207 to indicate various system power operating modes discussed further below. In some embodiments, power subsystem 110 may monitor the health of power distribution (e.g., voltage and current) to ensure safe operation and manage battery power management (e.g., charging and discharging). Power subsystem 110 delivers power to wireless foot switch charger 215 and surgical tool subsystem 116 based on input from upstream regulator PCBAs 211, 213. Power subsystem 110 transmits the state of the power subsystem to the upstream regulator PCBA.

[0030] In some embodiments, the power subsystem 110 includes an AC power input module 205. In some embodiments, the AC power input module 205 receives a rated AC mains input (e.g., 100 VAC to 240 VAC / 50 Hz to 60 Hz) from a wall outlet via a power cord to an inlet outlet (e.g., IEC 60320 type C20, etc.) and switches the filtered AC input to the control panel 100. For example, in some embodiments, this switching and filtering may be facilitated via a J30 connector in the lower PCBA 211.

[0031] In some embodiments, the AC power input module 205 has a built-in medical-grade EMI (electromagnetic induction) filter with very low leakage current (e.g., <5 μA) (microamps), which suppresses electromagnetic noise transmitted through conduction. In some embodiments, the AC power input module 205 may include a 2-pole (live and neutral) circuit breaker switch that switches the filtered AC to the control panel.

[0032] In some embodiments, the AC power input module 205 may advantageously be rated to handle a current of 20 A at 250 VAC (other power input module ratings may also be used). The dielectric test voltage rating of the AC power input module 205 between the live / neutral terminal and the protective ground terminal may advantageously exceed the electrical isolation requirements of system 10, which may be, for example, 1500 VAC.

[0033] like Figure 2As shown, the power subsystem 110 includes a main power supply unit (PSU) 221 that communicates with the lower PCBA 211, and in some embodiments, this communication may be via a connector. In some embodiments, the power subsystem 110 may receive AC input (live, neutral, and ground) from the lower PCBA 211. In some embodiments, this AC input may advantageously be routed through the PSU 221 and terminate at a J4 connector, from which the PSU 221 receives the AC input via an AC busbar, such as... Figure 2 As shown.

[0034] In some embodiments, PSU 221 can accept a rated AC mains input (e.g., 100 VAC-240 VAC / 50Hz-60 Hz) and convert this input into an isolated DC output voltage (e.g., 24VDC, 12VDC_standby) to drive the secondary circuitry of console 100. This isolated DC output voltage complies with the leakage current requirements for Type BF applications in both patient protection measures (2MOPP) and the IEC 60601-1 third edition medical safety standard (e.g., < 500 uA).

[0035] When the AC input is within acceptable limits, the PSU 221 defaults to supplying a 12 VDC_standby output (secondary voltage). The maximum rated current that can be drawn from the 12 VDC_standby output is 0.5 A (other maximum rated currents are also envisioned). The 12 VDC_standby output can be used to power the power control circuitry in the power subsystem 110, such as the 5 V / 3.3 V DC-DC regulator, controller 103, and standby switch 207.

[0036] In some embodiments, the isolated DC output (24 VPS) from PSU 221 can be used as the main voltage to power console subsystem modules (such as surgical tool subsystem 116). PSU 221 can deliver a 24 VDC output with, for example, a tolerance of ±5%. The maximum rated current that can be drawn from the 24 VDC output can be 50 A. This current is equivalent to 1200 watts of power that can be delivered from PSU 221. Other PSU sizes, output power, maximum rated current, and tolerances can also be utilized depending on power requirements.

[0037] In some embodiments, the PSU 221 advantageously delivers, for example, up to 918 W of continuous output power at, for example, a 24 VDC output. In this embodiment, to meet the worst-case output power of 918 W at a 90 VAC input, the conversion efficiency of the PSU 221 can be set to at least 85%. (918 W (output power) / 85% = 1080 W input power at the PSU). This efficiency is equivalent to the PSU drawing 12 A of AC input current at 90 VAC (12 A × 90 VAC = 1080 W). Since 12 A is 80% of 15 A, the console 100 can advantageously operate through any 15 A AC input wall socket in the world. Other conversion efficiencies, input power, and input currents can also be used.

[0038] In some embodiments, PSU 221 has an AC input to DC output conversion efficiency of up to, for example, 94%, and delivers, for example, at least 1200 W of continuous output power at 24 VDC output. For example, in some embodiments, after pressing the switch in AC power input module 205, the 24 VDC output of PSU 221 to a subsystem (e.g., surgical tool subsystem 116) is enabled by default via the system power PCBA hardware, even when the system power PCBA is not programmed. When the system power PCBA is programmed, it may be necessary to press standby switch 207 to enable the 24 VDC output of PSU 221 to the subsystem hardware (e.g., surgical tool subsystem 116).

[0039] In some embodiments, PSU 221 may include the following I / O control and status signals (24 VDC power good status, 24 VDC remote on / off control) that interface with the I / O (input / output) pins of controller 103. These I / O pins can be used to sense the health status of the 24 VDC output and enable / disable the 24 VDC output voltage.

[0040] Under full load conditions, from the moment the input AC voltage drops below an acceptable range, PSU 221 maintains, for example, 90% of the 24 VDC output for at least, for example, 13 ms. (Other full load conditions are also envisioned (e.g., 70%, 80%, 95% of 24 VDC, etc.).) Other time periods are also envisioned (e.g., 5 ms, 10 ms, 15 ms, 20 ms, 50 ms, etc.). In some embodiments, 8 ms after the moment the input AC voltage drops below an acceptable range, PSU 221 decrements the 24 VDC power-good I / O signal. Other timings are also envisioned (e.g., 5 ms, 7 ms, 10 ms, etc.). The remaining 5 ms (i.e., 13 ms–8 ms) duration can be used by controller 103 and / or power subsystem 110 to seamlessly switch to instantaneous battery backup power to support backup power requirements (e.g., normal system functions, etc.) for, for example, 1.5 ± 0.5 seconds.

[0041] The PSU 221 can support the industry-standard PMBus (Power Management Bus) command protocol, which enables the controller 103 to communicate with the PSU 221 via the I2C bus to read one or more parameters of the system 10. Some embodiments may include the following system 10 parameters: AC input voltage, DC output voltage (24 VDC, 12 VDC_standby), AC input current, DC output current (24 VDC), power health status, fan and power supply temperature, overvoltage and / or overcurrent, and voltage out-of-specification conditions.

[0042] In some embodiments, when the console receives AC mains voltage from the wall (by turning on the rocker switch in the AC power input module 205), the PSU can by default supply 12 VDC_standby voltage (unrelated to enabling the 24 VDC output from the PSU) to the system power PCBA via its J8 connector. When the system power PCBA is not programmed, and AC from the AC power input module 205 is available to the PSU, 24 VDC (24 VPS) from the PSU 221 is enabled to the subsystem by default (even if the standby switch is not pressed). This is achieved by hardware logic in the system power PCBA that drives the 24 VPS output enable pin low (-PS_INHIBIT) to output 24 VPS from the PSU to support powering the host module, even if the system power PCBA is not programmed. This feature also facilitates programming the logic in the system power PCBA from the host module. If the system power PCBA is programmed, the standby switch must be pressed to enable the 24 VDC output from the PSU to the subsystem hardware (e.g., the host PC (personal computer) module).

[0043] like Figure 2As shown, the power subsystem 110 includes an ORing circuit 223 that combines the DC output (e.g., 24 VPS, 12V_standby) from the PSU 221 with a battery pack 209 (e.g., at 32.4 VDC) by paralleling power supplies to provide system redundancy. The output voltage from the ORing circuit 223 (e.g., 12 VDC to 32.4 VDC) powers the power regulator 225 to deliver 3.3 VDC and 5 VDC, for example, circuitry such as the controller 103, standby switch 207, and wireless foot switch 214 proximity sensor. In some embodiments, one purpose of the ORing circuit 223 is to ensure that the controller 103 is given priority power.

[0044] As a parallel path, the output voltage (e.g., 12-32.4 VDC) from ORing circuit 223 powers (multiple) power regulators 227 to supply, for example, 3.3 VDC and 5 VDC to circuits such as wireless foot switch charger 215. When console 100 is in standby or deep sleep power mode, controller 103 shuts off power to peripheral devices by disabling power regulators 225, 227 to consume less power.

[0045] In some embodiments, the standby switch 207 includes embedded logic. For example, to force the console to shut down, when a user presses the console standby switch 207 for more than, for example, 5 seconds (also known as a long press), the controller 103 or the controller of the power subsystem 110 can disable the main DC output (24 VPS) of the PSU 221 regardless of concurrent operation. Additionally, the standby switch 207 logic can reset the controller 103 and prevent the system electronics from being powered by the battery pack voltage.

[0046] In some embodiments, the power subsystem 110 and / or controller 103 may include a 32-bit ARM (Advanced RISC (Reduced Instruction Set Computer)) based microcontroller that monitors, controls, and communicates with components of the system 10. In some embodiments, controller 103 and / or power subsystem 110 may operate at a 40 MHz input clock supplied by an external crystal oscillator. Voltage monitoring circuitry monitors the health of subsequent DC voltages and initiates an interrupt to controller 103 when these voltages drop to, for example, below 5% of the corresponding DC voltage. A reduced version of the subsequent voltage is fed to the ADC (Analog-to-Digital Converter) pin of controller 103 for sensing the health of the voltage. In some embodiments, power subsystem 110 monitors the DC output current (at 24 VDC) supplied from PSU 221 and may also monitor voltages and currents from battery pack 209 output and foot switch charger 215.

[0047] In some embodiments, controller 103 communicates with various components via CAN (Controller Area Network) bus 210. In some embodiments, controller 103 can be programmed via JTAG (Joint Test Action Group) port (J6). CAN bus 210 can be used to update the ARM bootloader or subsystem application of controller 103. In some embodiments, controller 103 / power subsystem 110 monitors the health status of the system voltage via a corresponding ADC interface, such as... Figure 2 As shown.

[0048] like Figure 2 As shown, 24 VDC from PSU 221 is fed to battery charger 230 to boost 24 VDC to 32.4 VDC (nominal) to 36 VDC for charging two or more battery packs 209. In the event of an AC input failure, buck regulator 224 reduces 33 VDC from the battery packs to 24 VDC to power system 10 from battery packs 209. The outputs of the boost and buck regulators are enabled / disabled by GPIO (general purpose input / output) pins of controller 103.

[0049] In some embodiments, controller 103 controls the operation of the lower PCBA 211 and the upper PCBA 213. In some embodiments, the lower PCBA 211 and the upper PCBA 213 may include a dedicated microcontroller, an FPGA (Field-Programmable Gate Array), etc. In some embodiments, controller 103 communicates with a fuel gauge IC embedded in the battery pack 209 via an I2C bus interface. In some embodiments, the fuel gauge ICs of the two battery packs may have the same device address, allowing controller 103 to communicate with the battery packs individually via, for example, an I2C multiplexer IC included in the lower PCBA 211. In some embodiments, controller 103 uses, for example, GPIO to individually charge the battery pack 209. For example, controller 103 monitors the SoC of each battery pack in the battery pack 209, and in some embodiments, charges one battery pack 209 at a time.

[0050] In some embodiments, controller 103 begins charging the battery packs when the corresponding SOC drops below 60%. If the SOC is above 60%, controller 103 maintains the SOC between each battery pack within, for example, 5% (or another selected value, such as 1%, 3%, 10%, 15%, etc.). When the SOC of a battery pack exceeds 60%, that battery pack will not be charged (in this embodiment). For example, in this embodiment, if the SOC of battery pack 109a is below 60% and the SOC of battery pack 109b is above 60%, controller 103 will begin charging battery pack 109a (which is below 60%) and keep the SOC within 5% of the SOC of battery pack 109b, and when the SOC reaches, for example, 80% (other values ​​are also possible, such as 70%, 75%, 85%, 90%, etc.), controller 103 stops charging the battery packs. The power subsystem 110 discharges either of the battery packs 109a and 109b to a minimum SoC of, for example, 30%, before putting the system 10 into deep sleep, thereby preventing further system discharge of the battery packs 109a and 109b. Other SoC levels before entering deep sleep are also possible (e.g., 5%, 10%, 20%, 25%, 35%, etc.). In some embodiments, the controller 103 allows or restricts charging of the battery pack 109 when the internal temperature of the battery pack is, for example, between 5°C and 45°C (other restricted charging temperature ranges are also possible depending on, for example, battery type, environment, etc.).

[0051] In the power subsystem 110, the maximum DC power consumed to charge each battery pack 109 under given conditions can be limited to, for example, 60 W. Other maximum DC power limits are also envisioned (e.g., 10 W, 20 W, 50 W, 75 W, 100 W, etc.). The battery charger 230 monitors the charging current of the battery packs 209. When the controller 103 detects that the battery packs are drawing more than, for example, 60 W for charging, as a safety feature, the controller 103 disables battery charging.

[0052] In some embodiments, the battery charger 230 performs trickle charging, wherein the battery pack 209 is charged with a charging current of, for example, 400 mA or less, until the battery voltage reaches, for example, 30 VDC. After reaching 30 VDC, the battery pack 209 is charged with a main charging current of, for example, 1.5 A. Other trickle charging currents (e.g., 250 mA, 500 mA, 700 mA, etc.) and battery voltage targets (e.g., 20 VDC, 35 VDC, 40 VDC, etc.) are also possible. Other main charging currents are also possible (e.g., 1 A, 2 A, 2.5 A, 5 A, etc.).

[0053] In some embodiments, controller 103 facilitates a switch from direct power to battery. In some embodiments, under full-load conditions, the power subsystem 110 can maintain, for example, 90% of the 24VDC output for at least 13 ms from the moment the input AC voltage drops below an acceptable range. Other full-load conditions are also envisioned, as described above. Eight ms after the moment the input AC voltage drops below an acceptable range, power subsystem 110 reduces the 24VDC power-good I / O signal. This signal triggers an interrupt to controller 103. The remaining 5 ms (i.e., 13 ms - 8 ms) duration can be used by controller 103 to seamlessly switch the buck-regulated battery pack output voltage (24V_BATT) to power the console subsystem for 1.5 seconds to ensure normal system function.

[0054] In some embodiments, the battery charger 230 monitors and regulates the battery charging current, and provides an interrupt to the controller 103 when it detects a fault condition during the charging of the battery pack 209. In some embodiments, the battery charger 230 activates a red LED (light-emitting diode) when it detects any fault (e.g., when the charging power drawn by the battery pack 209 exceeds 60 W). When the battery charging is within an acceptable threshold level, the battery charger 230 activates a green LED.

[0055] In some embodiments, the controller 103 and the power subsystem 110 ensure that one battery pack 109 does not charge another battery pack when the battery packs are connected in parallel by adjusting the voltage across each battery pack. When the battery packs 109 are connected in parallel, the voltage across each battery should be the same.

[0056] In some embodiments, two battery packs can be allowed to discharge independently while maintaining balance between the two packs and ensuring optimal performance. In some embodiments, this involves using one or more diodes. A diode is a semiconductor that allows current to flow in one direction but not in the other. In this arrangement, the diodes are strategically positioned to prevent current from flowing back from one battery pack to another. Each battery pack 209 in the system is connected to a shared load via one or more diodes disposed, for example, in an ORing circuit 223. This placement ensures that the current supplied by each battery pack flows only to the shared load and not back to the other battery pack. Therefore, each battery pack operates independently, thereby preventing one battery from charging another.

[0057] The power subsystem 110 also includes real-time monitoring of the voltage across each battery pack. If the voltage difference between the two battery packs is significant (greater than a certain threshold), the power management controller can intervene and switch the charging process to balance the System-on-Chip (SoC) between the two battery packs. If the battery voltage drops too low or rises too high, a switch can advantageously disconnect the battery from the circuit. Disconnecting the battery in this way protects each battery from potential damaging conditions and helps maintain balanced operation.

[0058] In some embodiments, the power subsystem 110 may be tightly integrated with the power management controller 103. The controller 103 continuously monitors the state of each battery pack and can control switching via the power subsystem 110 based on the feedback it receives. This functionality ensures efficient and balanced use of power from both battery packs, while also protecting the battery packs from damaging conditions and helping to maintain balanced operation between the two battery packs. This balancing operation can extend battery pack life, improve system reliability, and ensure constant power delivery. By preventing one battery from charging another and avoiding potential damaging conditions, the power subsystem 110 and controller 103 significantly improve the safety of the system 10.

[0059] Advantageously, the controller 103 and power subsystem 110 operate each battery pack independently, integrating diodes for voltage monitoring and switching control to maintain state-of-charge balance, extend system life, and ensure safe operation. Therefore, when one battery has a higher charge level (higher voltage), the higher-voltage battery may begin to charge another less-charged battery (lower voltage). To avoid this, the controller 103 continuously monitors the voltage across each battery pack and adjusts the input or output of each battery to ensure their voltage levels are equal.

[0060] In some embodiments, controller 103 and power subsystem 110 can manage the switching between an immediate battery backup mode and an extended battery backup mode. For example, during an AC power failure, controller 103 first activates the immediate backup mode, in which two battery packs are connected in parallel to deliver a peak power output of, for example, 625 W for 2 seconds. After this period, controller 103 checks whether AC power has been restored. If not, the controller switches to the extended battery backup mode. In this mode, the battery packs deliver a lower power output of, for example, 145 W at 24 VDC, thereby extending the backup time to, for example, 5.5 minutes. This switching is based on a preset time limit and is triggered based on the state of the AC power supply. In some embodiments, controller 103 is configured to activate the extended battery backup mode when the battery pack's SoC is, for example, 21%.

[0061] In some embodiments, the decision-making process of the controller 103 for charging one battery pack at a time can be based on the SoC of each battery pack. The controller 103 continuously monitors the SoC of each battery pack and selects the battery pack with the lower SoC to charge first. Charging one battery pack at a time allows the controller 103 to better control the SoC of each battery pack and maintain a balance between the battery packs.

[0062] Advantageously, the 5% SoC difference is a buffer set by controller 103 to ensure balance between battery packs while still allowing slight differences in charging and discharging rates. If the SoC difference between battery packs becomes greater than 5%, controller 103 can interpret this as an imbalance and initiate corrective measures, such as charging the lower SoC battery pack or discharging the higher SoC battery pack to maintain balance. However, if the SoC difference is less than 5%, controller 103 interprets this as an acceptable difference and continues to monitor the battery packs without taking additional action. Other SoC differences (e.g., 1%, 3%, 7%, 10%, etc.) are also envisioned.

[0063] Setting an 80% SoC charging limit extends battery pack life. For example, in some embodiments, battery pack 109 may include lithium-ion batteries, which, while highly efficient, can suffer stress and potential damage if repeatedly charged to their maximum capacity. By setting the SoC charging limit to 80% SoC, controller 103 helps maintain battery health, thereby improving battery life and reliability. Furthermore, this limit creates a buffer that allows the battery pack to adapt to sudden power demands without overstressing it. This limit, combined with the balance maintained between battery packs, ensures efficient power management of the surgical console. Other SoC charging limits (e.g., 75%, 85%, 95%, etc.) may also be used.

[0064] The controller 103 also predicts and manages power demands. Given the critical functionality of the surgical console 100, it cannot withstand power interruptions. Therefore, in some embodiments, the controller 103 uses predictive analytics based on historical power consumption data, battery health indicators, and real-time power demands to effectively determine when to switch power or initiate a charging sequence. This prediction ensures an uninterrupted power supply to the console while optimizing battery performance.

[0065] In addition to battery health and power requirements, the power subsystem 110 also incorporates appropriate protection measures to safeguard the battery pack from potential damage. The controller 103 and power subsystem 110 continuously monitor battery temperature, voltage, and current to prevent overheating, overcharging, and over-discharging that could damage the battery pack. If any parameter exceeds safety limits, the controller 103 activates protective measures that may include reducing the charging rate, disconnecting the battery, or switching to another battery pack.

[0066] Because controller 103 manages multiple battery packs, it must also manage the possibility of uneven wear between battery packs 109. Controller 103 can implement processes for rotating which battery pack is charged or discharged first during use. This rotation ensures that the two battery packs experience similar levels of wear over time, thus promoting a more balanced lifespan and efficiency. In some embodiments, controller 103 can also play a role in maintenance and fault detection. By monitoring various battery health parameters, controller 103 can detect potential faults or degradation in battery packs 109, including changes in internal battery resistance, capacity decay, or abnormal temperature changes. Upon detecting such an anomaly, controller 103 can warn the user or initiate preemptive measures to prevent potential power failures.

[0067] Advantageously, the controller 103 is also adaptable to scalability, allowing more battery packs 109 to be included as needed. This scalability can be particularly valuable for future iterations of the surgical console 100 that may require higher power backup. By maintaining a design capable of handling multiple battery packs, the controller 103 ensures that the console design remains adaptable and future-proof.

[0068] Now for reference Figure 3 , combined Figure 1A , Figure 1B , Figure 2 , Figure 3 A flowchart corresponding to the charging process 300 is shown. The charging process 300 is implemented by system 10 via controller 103 and power subsystem 110. The charging protocol of system 10 includes four main operating states: start, switch, equalize, and stop. These operating states are described below in the context of boxes 300 to 314, and will be described in detail below.

[0069] At 302, controller 103 determines the conditions for starting charging by checking whether any of the battery packs 109 SoCs is less than an initial SoC threshold (e.g., 60%) or whether the difference in initial SoCs between any two battery packs 109 is greater than an initial SoC difference (e.g., 5%). If any of these conditions are met, controller 103 initiates the charging process, and the process proceeds to 304. Other initial SoCs are also envisioned (e.g., 20%, 40%, 70%, 85%, etc.). Other initial SoC differences to be looked for are also envisioned (e.g., 1%, 3%, 7%, 10%, etc.).

[0070] At 304, the initial charging state is entered when the SoC of any battery pack 109 is less than the initial SoC threshold or if the SoC difference between any two battery packs 109 is greater than the initial SoC difference.

[0071] At 306, controller 103 determines whether any battery SoC is greater than a predetermined SoC limit, such as 80%. If any battery's SoC is greater than the predetermined SoC limit, controller 103 begins charging the battery with the lowest SoC and enters a "switch" charging state at 308. If not, controller 103 determines whether there is a predetermined SoC difference between at least two battery packs greater than, for example, 5%. ("80%" and "5%" are given as examples. Other values ​​may also be used.)

[0072] In the "switching" charging state, when the SoC of the battery being charged is, for example, 3% larger than the SoC of the idle battery, the controller 103 switches charging between battery packs 109. If the predetermined SoC difference between battery packs 109 is greater than, for example, 5%, the controller 103 enters the "equalizing" charging state at 310, and the process proceeds to 312. If it is not greater than 5%, the controller 103 remains in the "switching" charging state.

[0073] At 312, in some embodiments, during a “balancing” charging state, controller 103 balances the charge levels among battery packs 109. If all battery packs 109 are above a predetermined SoC limit (e.g., 80%), controller 103 discharges the higher-capacity battery pack 109. If one of the battery packs 109 is above the predetermined SoC limit (e.g., 80%), controller 103 discharges that battery pack and charges the other battery pack 109 until the predetermined SoC limit is reached.

[0074] At 314, controller 103 then determines whether all battery pack SoCs are above a predetermined SoC limit (e.g., 80%) and whether the SoC difference between battery packs is less than a predetermined SoC difference (e.g., 5%). If all battery pack SoCs are above the predetermined SoC limit (e.g., 80%) and the SoC difference between battery packs is less than the predetermined SoC difference (e.g., 5%), controller 103 disables battery charging and equalization and enters a "stop" charging state.

[0075] At 316, controller 103 returns to the previous step and repeats the process until the stop condition is met.

[0076] In some embodiments, during the charging operation, 310 may follow 302, and 312 may follow 310. In certain specific embodiments, 302, 310, and 312 may be repeated.

[0077] Therefore, the above embodiments are scalable, allowing for the inclusion of more battery packs as needed, thus ensuring the console design remains adaptable and future-proof. The embodiments described herein manage and optimize power delivery, battery health, and system reliability, ensuring the surgical console performs its critical functions without interruption. The adaptability and scalability of the embodiments described herein make this surgical console ready to meet future power demands and potential design upgrades.

[0078] In the claims, any reference numerals in parentheses should not be construed as limiting the claims. The words “comprising” or “including” do not exclude the presence of elements or steps other than those listed in the claims. In an apparatus claim listing several devices, several of these devices may be implemented by the same hardware. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. In any apparatus claim listing several devices, several of these devices may be implemented by the same hardware. The fact that certain elements are recited in different dependent claims does not indicate that these elements cannot be used in combination.

[0079] While the description provided above is based on embodiments currently considered most practical and preferred, and details are provided for illustrative purposes, it should be understood that such details are for this purpose only, and this disclosure is not limited to the explicitly disclosed embodiments, but rather is intended to cover modifications and equivalent arrangements falling within the spirit and scope of the appended claims. For example, it should be understood that this disclosure contemplates that, to the extent possible, one or more features of any embodiment may be combined with one or more features of any other embodiment.

Claims

1. A surgical system comprising: At least two battery packs; Power subsystem, the power subsystem being configured as follows: During standby mode, the at least two battery packs are connected in parallel. In non-standby mode, disconnect at least two battery packs, and During parallel operation, prevent each of the at least two battery packs from charging different battery packs in the at least two battery packs; as well as A controller configured to individually charge each of the at least two battery packs to a power capacity equal to or less than a predetermined power capacity.

2. The surgical system of claim 1, wherein, Each of the at least two battery packs provides an output of 32.4VDC and delivers a current of 2.7 Ah.

3. The surgical system of claim 1, wherein: The predetermined power capacity is 100 Wh (watt-hours); and Each of the at least two battery packs delivers up to 87.48 Wh of power when fully charged.

4. The surgical system of claim 1, wherein, The controller is further configured to limit the state of charge (SoC) of each of the at least two battery packs to 80% during charging.

5. The surgical system of claim 1, wherein, The controller is further configured to switch to an instant battery backup mode during an AC (alternating current) input failure, wherein the at least two battery packs provide a peak pulse discharge power of at least 625 W at 24 VDC for up to 2 seconds.

6. The surgical system of claim 5, wherein, The controller is further configured to switch to an extended battery backup mode after the immediate battery backup mode if the AC input remains unavailable, to deliver 145 W of power at 24 VDC from the at least two battery packs for 5.5 minutes or until the at least two battery packs are depleted to support the power supply of the constrained subsystem.

7. The surgical system of claim 6, wherein, The controller is further configured to activate an extended battery standby mode when the state of charge (SoC) of the battery pack is 21%.

8. The surgical system of claim 1, wherein, The controller is further configured to switch the operation of the at least two battery packs to parallel mode only when seamless instantaneous standby is required.

9. The surgical system of claim 1, wherein, The power subsystem includes one or more diodes for preventing current backflow between the at least two battery packs.

10. The surgical system of claim 1, wherein, The controller is further configured to charge or discharge the at least two battery packs to maintain the state of charge (SoC) within a set range.

11. A battery management method for a surgical system, comprising: Determine the state of charge (SoC) of at least two battery packs. When the difference between the SoCs of the at least two battery packs is greater than a predetermined SoC difference, the SoCs of the at least two battery packs are balanced. as well as When the SoC of one of the at least two battery packs is greater than a predetermined SoC limit and the SoC of the other battery packs is less than the predetermined SoC limit, the one battery pack is discharged to the predetermined SoC limit and the other battery packs are charged to the predetermined SoC limit. Each battery pack has a power capacity equal to or less than the predetermined power capacity.

12. The battery management method as described in claim 11, wherein, The predetermined power capacity is 100 Wh, the predetermined SoC difference is 5%, and the predetermined SoC is limited to 80%.

13. The battery management method as described in claim 11, wherein, Determining the SoC includes determining an initial SoC for each of the at least two battery packs, and the battery management method further includes: When the initial SoC of one of the at least two battery packs is less than 60%, the at least two battery packs are charged to 80% SoC; and When the difference between the initial SoC of the at least two battery packs is greater than 5%, the at least two battery packs are charged to 80% SoC.

14. The battery management method of claim 11, further comprising: When the difference between the SoCs of the at least two battery packs is greater than 3%, the charging of the at least two battery packs to 80% SoC is switched.

15. The battery management method of claim 11, further comprising: During charging, charging is stopped when the SoC of at least two battery packs is greater than 80% and the difference between the SoCs of at least two battery packs is less than 5%.

Images