Multi-module portable power station

Abstract

The present invention relates to a multi-module portable power station. A method of operating a portable power station including a plurality of battery modules and a battery management system operably connected to the plurality of battery modules, the method including: using the battery management system to supply a charging current generated from a mains power operably connected to an AC input connection of the portable power station to at least one first battery module of the plurality of battery modules; and using the battery management system to electrically connect at least one second battery module of the plurality of battery modules to a load so as to supply operating current to the load. The method further includes using the battery management system to electrically disconnect at least one third battery module of the plurality of battery modules from the charging current and the load so as to thermally manage the at least one third battery module.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the field of electrical power supply and, in particular, to portable power stations that supply electrical energy from electrochemical cells. BACKGROUND

[0002] Portable power stations supply energy to electrical devices such as power tools, computer devices, and any other electrical devices. The portable power stations include rechargeable electrochemical cells (i.e., batteries) that store electrical energy. Depending on the capacity of the power station, the electrical energy is provided in any desired format such as low voltage DC, high voltage DC, and line voltage AC (i.e., 120 V or 240 V).

[0003] Generally, portable power stations are used when it is not possible to connect to a utility-provided source of electrical power, for example, during the initial construction phase of a building or house, or in remote areas where it is expensive or inconvenient to connect to utility-provided electrical energy. Also, portable power stations are used in areas where operation of a generator powered by a portable internal combustion engine is prohibited due to noise and pollution restrictions. Battery-powered power stations operate substantially silently and do not emit harmful exhaust products.

[0004] Known portable power stations include a battery unit and a corresponding charging device. The charging device restricts operation of the power station during charging and generally does not take into account the user’s desire to quickly charge the power station to meet an urgent power demand. Therefore, further development of portable power stations is desirable. SUMMARY

[0005] According to an exemplary embodiment of the present disclosure, a method of operating a portable power station including a plurality of battery modules and a battery management system operably connected to the plurality of battery modules, the method comprising: supplying, using the battery management system, a charging current generated by a main electricity connected to an AC input connection of the portable power station to at least one first battery module of the plurality of battery modules; and electrically connecting, using the battery management system, at least one second battery module of the plurality of battery modules to a load so as to supply operating current to the load. The method further comprises disconnecting, using the battery management system, at least one third battery module of the plurality of battery modules from the charging current and the load so as to thermally manage the at least one third battery module. The at least one first battery module, the at least one second battery module, and the at least one third battery module are located in an enclosure of the portable power station.

[0006] According to another example embodiment of the present disclosure, a portable power generation station for supplying electrical energy to a load includes a housing, a plurality of battery modules, and a battery management system. The housing includes an AC input connection. The plurality of battery modules are located within the housing. The battery management system is operably connected to the plurality of battery modules. The battery management system is configured to (i) electrically connect at least a first battery module of the plurality of battery modules to a charging current generated by the battery management system from a mains power coupled to the AC input connection, (ii) electrically connect at least a second battery module of the plurality of battery modules to the load so as to supply operating current to the load, and (iii) electrically disconnect at least a third battery module of the plurality of battery modules from the mains power and the load so as to thermally manage the at least a third battery module. BRIEF DESCRIPTION OF DRAWINGS

[0007] The above features and advantages and other features and advantages of the present application are readily apparent as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0008] Figure 1 is a block diagram of a tool system as disclosed herein including a portable power generation station operably connected to a mains power and an electrical load;

[0009] Figure 2 is a block diagram of a switching system and battery modules of the portable power generation station of Figure 1

[0010] Figure 3 is a flowchart illustrating an example method of operating the portable power generation station of Figure 1

[0011] Figure 4 is a block diagram of six battery modules of the portable power generation station of Figure 1

[0012] Figure 5 is a block diagram of six battery modules of the portable power generation station of Figure 1

[0013] Figure 6 is a block diagram of six battery modules of the portable power generation station of Figure 1 DETAILED DESCRIPTION

[0014] ​​​​​For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is emphasized that no limitation on the scope of the present disclosure is intended to be rendered by utilizing the illustrative embodiments, examples of which are illustrated and described herein. It is also to be understood that the present disclosure is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. Rather, the application is capable of other embodiments and of being practiced or being carried out in various ways.

[0015] Aspects of the present disclosure are disclosed in the accompanying description. Alternative embodiments of the present disclosure will be evident to those of ordinary skill in the art and can be made without departing from the scope and spirit of the present disclosure. It will be apparent to those skilled in the art that the present disclosure can be practiced without the specific details set forth herein. It is also intended that the present disclosure cover all alternatives consistent with the principles of the present disclosure.

[0016] For the purposes of the present disclosure, the phrase "A and / or B" means (A), (B), or (A and B). For the purposes of the present disclosure, the phrase "A, B, and / or C" means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

[0017] As used with respect to embodiments of the present disclosure, the terms "including," "containing," "having," and the like are synonymous.

[0018] As Figure 1 As shown in FIG. 1, the tool system 100 includes a portable power generation station 104 for supplying electrical energy to electrical loads 108. Exemplary electrical loads 108 include an AC power tool 112, a DC power tool 116, and a battery charger 120. The AC power tool 112 is, for example, a power tool that includes an AC motor that uses 120 v or 240 v AC power at a frequency of 60 Hz (i.e., line power 124, main power, line voltage, or mains voltage). In one embodiment, the AC power tool 112 is a portable circular saw (i.e., a portable power tool), and in another embodiment, the AC power tool 112 is a table saw. The AC power tool 112 can be supplied with AC electrical power from the AC output connection 128 of the portable power generation station 104 or directly from the line power 124.

[0019] The DC power tool 116 of load 108 is, for example, a portable power tool that includes a brushed or brushless motor that uses DC power at a voltage of 12 V to 60 V. In one embodiment, the DC power tool 116 receives DC power either from a corresponding connected battery pack (not shown) or via a wired connection to the DC output connection 132 of the portable power station 104.

[0020] The battery charger 120 of load 108 is, for example, a device for charging the batteries (i.e., battery pack 136) of other DC power tools and DC power tool 116. In one embodiment, AC power from AC output connection 128 or directly from mains power 124 is supplied to the battery charger 120 to charge the battery pack 136 operatively connected to the battery charger 120. Alternatively, DC power from DC output connection 132 is supplied to the battery charger 120 to charge the battery pack 136. Any one or more of the power tools 112, 116, and 120 of load 108 can be simultaneously connected to the portable power station 104 and simultaneously supplied with electrical energy from the portable power station 104, so that tools 112, 116, and 120 are available simultaneously.

[0021] The portable power station 104 is an energy storage device and is also known as a cordless generator and mobile power source. For example... Figure 1 As shown, the portable power station 104 includes a housing 140 that houses an AC input connection 144, multiple battery modules 148, a battery management system 152, an AC output connection 128, a DC output connection 132, and an active cooling system 156. The battery management system 152 (“BMS”) is a common control electronics unit that intelligently charges the battery modules 148, intelligently selects a predetermined number of battery modules 148 to supply power to the load 108, and intelligently determines when one of the battery modules 148 should be taken offline for repair or replacement. The BMS 152 includes a switching system 160, an energy output unit 164, a charging unit 168, and a current flow sensor 172, each operatively connected to a controller 176. Each component of the portable power station 104 is described herein.

[0022] like Figure 1As shown, the AC input connector 144 is configured to be electrically connected and physically connected to an AC power source, such as mains power 124 from a corresponding wall socket (not shown). The AC input connector 144 receives AC power input to the portable power station 104. In one embodiment, for example, the AC input connector 144 is a 3-pin NEMA (Institute of Electrical Manufacturers) connector for the North American market. Alternatively, the AC input connector 144 may have any other connector format, such as that commonly used in the corresponding market or region.

[0023] AC output connector 128 is configured to electrically and physically connect to AC-powered devices, such as AC power tools 112 and battery chargers 120. AC output connector 128 typically has the same connection format as a standard wall socket, such as a 3-pin NEMA connector in North America. Alternatively, AC output connector 128 may have any other connector format, such as that commonly used in the corresponding market or region. Furthermore, AC output connector 128 may include multiple connectors, such that more than one AC-powered device can be directly connected to portable power station 104.

[0024] The DC output connector 132 is configured to be electrically and physically connected to a DC-powered device, such as the DC power tool 116. In one embodiment, the DC output connector 132 has at least one female "cigarette lighter plug," as commonly found in automobiles. Alternatively, the DC output connector 132 may have any other connector format, such as that commonly used in the corresponding market or region. Moreover, the DC output connector 132 may include multiple connectors, such that more than one DC-powered device can be directly connected to the portable power station 104.

[0025] like Figure 2 As shown, each battery module 148 includes a plurality of battery cells 180 located within a housing 184 and an interface 188. Figure 2 The ellipse in the figure represents that the battery module 148 may include any number of battery cells 180, and the portable power station 104 may include any number of battery modules 148. In an exemplary embodiment, each battery module 148 includes ten of the battery cells 180, and the portable power station 104 includes six of the battery modules 148.

[0026] The battery units 180 are electrically connected to each other and to the interface 188. In one embodiment, each battery module 148 includes the same number of battery units 180, which number is from four to forty. The battery modules 148 can include any combination of series and parallel connected battery units 180. For example, in one embodiment, each battery module 148 includes ten battery units 180 connected in series. In another embodiment, each battery module 148 includes two groups of ten battery units 180 connected in series, and the two groups are connected in parallel. The battery modules 148 include any other electrical configuration of battery units 180.

[0027] In one embodiment, each battery unit 180 is a rechargeable lithium-ion polymer (Li-ion polymer or LiPo) battery unit having a nominal voltage of approximately 3.7 V. In other embodiments, the battery units 180 are nickel-cadmium (NiCd), nickel-metal hydride (NiMH), lead-acid, lithium-ion (Li-ion), or any other desired rechargeable battery architecture. Generally, the battery units 180 have a battery architecture with a high power density, but they are also lightweight so as to make the portable power station 104 easy to transport. In one embodiment, the portable power station 104 can include battery units 180 of a first architecture and battery units 180 of a second, different architecture. For example, the portable power station can include some battery modules 148 having battery units 180 with a LiPo architecture and other battery modules 148 having battery units 180 with a lead-acid architecture.

[0028] Each battery module 148 also includes a voltage / temperature sensor 192 operably connected to each battery unit 180 and to the interface 188. The voltage / temperature sensor 192 detects the voltage and temperature of the corresponding battery unit 180 and generates an electrical output. The electrical output of each voltage / temperature sensor 192 is operably connected to the BMS 152 through at least the switching system 160. The voltage / temperature sensors 192 configure the portable power station 104 to individually monitor the temperature and voltage of each battery unit 180 in the portable power station 104. The voltage / temperature sensors 192 are electrically connected to the interface 188.

[0029] Each battery module 148 can be individually removed and replaced from the housing 140 of the portable power station 104. When a battery module 148 is connected to the portable power station 104, the interface 188 is physically and electrically connected to a corresponding interface 196 of the switching system 160 of the BMS 152. Removing a battery module 148 from the portable power station 104 includes disconnecting the interface 188 from the interface 196 and removing the disconnected battery module 148 from the housing 140. Connecting a battery module 148 to the portable power station 104 includes placing the battery module 148 within the housing 140 and connecting the interface 188 to the interface 196.

[0030] As shown in Figure 1 The switching system 160 of the BMS 152 is electrically connected to at least each battery module 148, the energy output unit 164, and the charging unit 168. In one embodiment, the switching system 160 is directly electrically connected to each battery module 148 using dedicated electrical connections and is configured to connect or disconnect any combination of the battery modules 148 to the energy output unit 164 and the charging unit 168. Through the switching system 160, there can be one or more active battery modules 148 to power the load 108 at any given time.

[0031] Referring again to Figure 2 In one embodiment, the switching system 160 includes a plurality of charging field effect transistors 204 (i.e., charging FETs), a plurality of working FETs 208, and a plurality of interfaces 196. The charging FETs 204 electrically connect and disconnect the battery modules 148 to the charging current output by the charging unit 168. The working FETs 208 electrically connect and disconnect individual battery modules 148 to the load 108 by the energy output unit 164. The charging FETs 204 and the working FETs 208 are electrically controlled by the controller 176 to be in a“closed” configuration that electrically connects the battery modules 148 or in an“open” configuration that electrically disconnects the battery modules 148. In other embodiments, the switching unit 160 includes any other type of electrically controlled switch.

[0032] The interfaces 196 of the switching system 160 are configured to electrically and physically connect to corresponding interfaces 188 of the battery modules 148. The interfaces 196 are provided in any desired interface type and structure. The switching system 160 includes at least as many interfaces 196 as the number of battery modules 148.

[0033] Referring again to Figure 1The energy output unit 164 of the BMS 152 includes an AC power supply 212 and a DC power supply 216. The AC power supply 212, also referred to as an "inverter" or "power inverter," is configured to convert the DC power of one or more battery modules 148 into AC power for supplying AC power to the load 108 via the AC output connection 128. The BMS 152 is configured to operate the switching system 160 and the energy output unit 164 to connect any one or more battery modules 148 to the AC power supply 212. In one embodiment, the AC power output from the AC power supply 212 matches the voltage and frequency of the mains power 124, such that the AC power tool 112 can operate from the portable power station 104 using energy from the battery modules 148. Furthermore, in some embodiments, the energy output unit 164 is configured to connect the mains power 124 directly to the AC output connection 128, such that AC power is supplied to the AC power tool 112 connected to the AC output connection 128 directly from the mains power 124 instead of from the battery module 148.

[0034] DC power supply 216 is electrically connected to DC output connection 132 and configured to supply DC power from battery module 148 to load 108 via DC output connection 132. BMS 152 is configured to operate switching system 160 and energy output unit 164 to connect any one or more battery modules 148 to DC power supply 216. In one embodiment, the DC power output from DC power supply 216 via DC output connection 132 is matched to a voltage used by DC power tool 116, such that DC power tool 116 can operate from portable power station 104 using energy from battery module 148.

[0035] like Figure 1 As shown, the charging unit 168 of the BMS 152 is configured to intelligently charge the battery module 148 using at least one corresponding charging current. Specifically, the charging unit 168 is configured to convert the mains power 124 into a DC charging current for charging the battery module 148. Moreover, in some embodiments, the charging unit 168 generates a charging current by transferring electrical energy from the first battery module 148 to the second battery module 148 in order to charge the second battery module 148 at the expense of discharging the first battery module 148.

[0036] The current sensor 172 of the BMS 152 is configured to monitor multiple currents. For example, the current sensor 172 is configured to monitor: (i) the current drawn from or supplied to each battery module 148; (ii) the current drawn from the portable power station 104 via the AC input connection 144; (iii) the current output via the AC output connection 128; and (iv) the current output via the DC output connection 132. The current sensor 172 is coupled to the controller 176 to provide sensed current data to the controller 176 for processing.

[0037] The controller 176 of the BMS 152 is configured to execute program instructions (i.e., software) to operate the portable power station 104 to supply electrical energy to the load 108, charge the battery module 148, and monitor the health of the battery module 148, among other functions. The controller 176 is operatively connected to the switching system 160, the energy output unit 164, the charging unit 168, and the current sensor 172. The controller 176 is provided as at least one microcontroller and / or microprocessor.

[0038] like Figure 1 As shown, the active cooling system 156 is operatively connected to the BMS 152 and includes at least one fan 224 and at least one controllable vent 228. The BMS 152 implements a thermal management strategy to determine whether charging or discharging of the battery module 148 results in thermal stress on the battery module 148. Thermal stress occurs when one or more of the battery modules 148 are operated (i.e., charged or discharged) when the temperature of the battery module 148 exceeds its normal operating temperature range (i.e., from approximately 20 °C to approximately 50 °C in one embodiment). In response to detecting a thermal problem, the BMS 152 is configured to transfer charging or discharging to different battery modules 148. Specifically, the BMS 152 is configured to use a voltage / temperature sensor 192 to monitor the temperature of each battery cell 180 of each battery module 148 and to regulate the temperature of the battery cells 180 and battery modules 148 by controlling airflow through the housing 140 of the portable power station 104. In one embodiment, each battery module 148 includes a corresponding fan in the fan 224 positioned to direct airflow across the battery module 148. In other embodiments, one or more battery modules 148 share the fan 224. The BMS 152 enables one or more fans 224 of the active cooling system 156 to cool the battery modules 148, and disables one or more fans 224 to increase the temperature of the battery modules 148 (e.g., when the portable power station 104 is operating in a cold environment) and the battery modules 148 are heated to the lower limit of the normal operating temperature range.

[0039] At least one vent 228 of the active cooling system 156 is formed in the housing 140 of the portable power station 104. The vent 228 is an electrically controllable opening through the housing 140. Specifically, each vent 228 can be configured to be fully closed, fully open, or in an intermediate position between the fully open and fully closed states. The BMS 152 is configured to control the state of the vent 228 to regulate the temperature of the battery cells 148. For example, the BMS 152 will typically configure the vent 228 to be fully open or partially open to increase airflow through the housing 140 to cool one or more of the battery modules 148. If one or more of the battery modules 148 should be heated, the BMS 152 will configure the vent 228 to be closed to trap heat generated by the battery modules 148 and the BMS 152. In one embodiment, the battery modules 148 are heated when the temperature of one or more of the battery modules 148 is below approximately 20°C.

[0040] During operation, the portable power station 104 is configured to perform... Figure 3 The flowchart shows method 300. See box 304 and attached reference. Figure 4 The portable power station 104 is configured to charge battery modules 148 identified as modules #1, #2, and #5. Each battery module 148 receives individually controlled charging current from the charging unit 168 until it is ready based on charging level and temperature. Specifically, at block 304, the portable power station 104 is electrically connected to the mains power 124 at the AC input connection 144. The BMS 152 configures the charging unit 168 to generate charging current from the mains power 124. Furthermore, the switching system 160 electrically connects the battery modules 148 identified as modules #1, #2, and #5 to the charging unit 168 to receive charging current. The battery modules 148 receive the charging current and charge until they are fully charged or until the connection to the mains power 124 is interrupted.

[0041] At frame 308, the portable power station 104 provides power to the load 108 by connecting the battery module 148 to the load 108. Figure 4The battery modules 148 identified as modules #6 are discharged. Specifically, the switching system 160 of the BMS 152 electrically connects the battery modules 148 identified as modules #6 to the DC output connection 132 to supply operating current to the load 108, i.e., the DC power tool 116. The portable power station 104 generates the operating current supplied to the load 108 while the portable power station 104 generates charging current supplied to the battery modules 148 identified as modules #1, #2, and #5. Thus, the BMS 152 charges some of the battery modules 148 while other battery modules 148 are being discharged.

[0042] Thereafter, at block 312, the portable power station 104 is configured to thermally manage the battery modules 148 identified as modules #3 and #4. Specifically, the BMS 152 electrically disconnects the battery modules 148 identified as modules #3 and #4 from the charging current of the charging unit 168 and the load 108 so that the battery modules 148 cool to the ambient temperature of the interior space within the housing 140 of the portable power station 104. Also, the BMS 152 can activate the active cooling system 156 to further cool the battery modules 148 being thermally managed by opening the vents 228 and / or activating the fan 224. The charging of block 304, the discharging of block 308, and the thermal management of block 312 occur simultaneously. Figure 4

[0043] At block 312, to thermally manage the battery modules 148, the BMS 152 monitors the temperature of each battery module 148 using the voltage / temperature sensors 192 associated with the battery cells 180. In one embodiment, the battery modules 148 have a normal operating temperature range from about 20 °C to about 50 °C, and the battery modules 148 should not be operated at temperatures above about 70 °C. When the BMS 152 determines that a monitored battery module 148 has a temperature that exceeds a predetermined temperature, the BMS 152 electrically disconnects the monitored battery module 148 having the temperature that exceeds the predetermined temperature from the charging current and the load 108 to cool the monitored battery module 148. An exemplary predetermined temperature is 45 °C and in other embodiments the predetermined temperature is from about 40 °C to about 55 °C. The predetermined temperature is selected to correspond to the upper limit of the normal operating temperature range of the battery modules 148. The monitored battery module 148 is disconnected using the switching system 160.

[0044] ​When the BMS 152 disconnects one of the battery modules 148 from the load 108 so that thermal management is disconnected from the battery module 148, the BMS 152 can connect a different battery module 148 to the load 108 so that the operational current supplied to the load 108 is interrupted. The BMS 152 connects a different battery module 148 to the load 108 that has a measured temperature below the predetermined temperature. Also, when the temperature of the disconnected and thermally managed battery module 148 drops below the predetermined temperature, the BMS 152 can reconnect the cooled battery module 148 to the load 108 and disconnect a different battery module 148 from the load 108.

[0045] In another embodiment, the BMS 152 is configured to connect one of the battery modules 148 to the load 108 for only a predetermined period of time and then disconnect the battery module 148 from the load 108. This approach prevents deep discharging of the battery cells 180 and thereby maintains battery life. For example, in one embodiment, the BMS 152 connects the battery module 148 identified as module #6 to the load 108 for a predetermined period of time. At the end of the predetermined period of time, the BMS 152 electrically disconnects the battery module 148 identified as module #6 from the load 108 and then electrically connects the battery module 148 identified as module #3 to the load 108. In this way, the battery modules 148 are more evenly depleted during use of the portable power plant 104 compared to switching to another one of the battery modules 148 after completely discharging one of the battery modules 148. Figure 4 In one embodiment, the BMS 152 connects the battery module 148 identified as module #6 to the load 108 for a predetermined period of time. At the end of the predetermined period of time, the BMS 152 electrically disconnects the battery module 148 identified as module #6 from the load 108 and then electrically connects the battery module 148 identified as module #3 to the load 108. In this way, the battery modules 148 are more evenly depleted during use of the portable power plant 104 compared to switching to another one of the battery modules 148 after completely discharging one of the battery modules 148.

[0046] For example, in one embodiment, the BMS 152 discharges each of the battery modules 148 to 80% and then discharges any one of the battery modules 148 below 80%. Then, the BMS 152 discharges each of the battery modules 148 to 60% and then discharges any one of the battery modules 148 below 60%. Next, the BMS 152 discharges each of the battery modules 148 to 40% and then discharges any one of the battery modules 148 below 40%. Then, the BMS 152 discharges each of the battery modules 148 to 20% and then discharges any one of the battery modules 148 below 20%.

[0047] Reference is made to Figure 5The portable power station 104 is operable to bypass the battery module 148 and use electrical energy from the mains power 124 to supply operating current to the load 108. In this manner, the BMS 152 directly converts the line voltage from the mains power 124 into the tool voltage required by the AC power tool 112, bypassing the battery module 148. For example, some users may connect the portable power station 104 to the mains power 124 to charge the battery module 148, while simultaneously connecting the load 108 to one or more of the AC output 128 and DC output 132. In such a configuration, the BMS 152 is operable to sense that the mains power 124 is connected and available, and then directly generate the operating current for the load 108 from the mains power 124 instead of drawing power from the battery module 148. Figure 5 In the example, portable power station 104 is connected to mains power 124. BMS 152 is charging battery modules 148 identified as modules #1, #2, #5, and #6, and battery modules 148 identified as modules #3 and #4 are being thermally managed and / or fully charged and cooled. Figure 5 In this configuration, BMS 152 has disconnected all battery modules 148 from load 108, and BMS 152 generates operating current for load 108 from trunk power 124. For example, BMS 152 uses the AC power supply 212 of energy output unit 164 to connect at least one AC operating current generated by trunk power 124 to AC output connection 128, and / or BMS 152 converts trunk power 124 to DC format, which includes at least one DC operating current using the DC power supply 216 of energy output unit 164 connected to DC output connection 132. Figure 5 In the example, the battery module 148 is not used to generate AC or DC operating current, and the portable power station 104 uses energy from the mains power 124 to provide unlimited operating time to the load 108.

[0048] refer to Figure 6 For example, BMS 152 has used two of the battery modules connected in parallel to generate the operating current for load 108. For instance, in some embodiments, BMS 152 determines the maximum power output level of each battery module 148 and the power requirement of load 108. BMS 152 then determines a predetermined number of battery modules 148 required to meet or exceed the power requirement of load 108. In this way, BMS 152 configures each battery module 148 to deliver less power than the maximum power output level, and the total power output level of the battery modules 148 is greater than the power requirement of load 108. Figure 6In the example of FIG. 1, the battery modules 148 identified as modules #2 and #6 are connected in parallel and coupled through the energy output unit 164 to the load 108 in order to deliver operating current to the load 108. The BMS 152 can connect any number of battery modules 148 in parallel to meet the power requirements of the load 108. In addition, the BMS 152 can connect any number of battery modules 148 in series to meet the power requirements of the load 108. Thus, the BMS 152 can form any combination of series and parallel connected battery modules 148 to meet the power requirements of the load 108.

[0049] Figure 6 It is also shown that the battery module 148 identified as module #3 has been taken offline. If one of the battery modules 148 is no longer performing within desired parameters, the BMS 152 is configured to exclude this battery module 148 from operation and instruct a user to recommend servicing the battery module 148. The remaining battery modules 148 continue to function without problems. For example, the BMS 152 is configured to determine a state of health of each battery module 148 and identify an unhealthy battery module 148 based on the determined state of health compared to a predetermined state of health. The state of health of the battery module 148 is determined by the BMS 152 based on factors including at least one of: a measured internal resistance, capacitance, voltage, ability to accept charge, number of charge-discharge cycles, age in use, temperature, and total energy charged and discharged. The factors used to determine the state of health are evaluated by the controller 176 and can be stored in a memory (not shown) of the BMS 152.

[0050] When the controller 176 identifies that one of the battery modules 148 has a state of health less than a predetermined state of health, the portable power plant 104 takes the battery module 148 offline and indicates to the user that a particular one of the battery modules 148 needs repair and / or replacement. When one of the battery modules 148 is taken offline, the switching system 160 has disconnected the battery module 148 from the AC input 144, the AC output 128, the DC output 132, the energy output unit 164, and the charging unit 168, so that no current is drawn from or supplied to the battery module 148. In one embodiment, when the user sees the indication about the offline battery module 148, such as on a corresponding display (not shown) of the portable power plant 104, the user removes the offline battery module 148 from the housing 140 by disconnecting the interface 188 from the interface 196. The user then inserts a healthy battery module 148 into the housing 140 by connecting the corresponding interfaces 188, 196. In this way, the portable power plant 104 can be repaired and configured to deliver a reliable source of electrical power to the load 108 when properly maintained. Additionally or alternatively, when the user sees the indication about the offline battery module 148, the user takes the portable power plant 104 to a service center for repair or replacement of the offline battery module 148. The service center is capable of repairing or replacing any component of the portable power plant 104; however, in one embodiment, the user can be limited to replacing the battery modules 148.

[0051] The portable power station 104 is configured to implement a fast charging process of the battery modules 148 for preparing the portable power station 104 for fast use. During the fast charging process, all of the battery modules 148 receive at least some charge before any of the battery modules 148 are fully charged. Such a process allows the portable power station 104 to be ready for use much faster than if each battery module 148 was charged to full charge in series. An exemplary fast charging process is presented below. First, the BMS 152 uses the switching system 160 to disconnect the battery modules 148 from the load 108. Afterward, using the charging units 168, the BMS 152 charges each battery module 148 to 50% capacity using a charging current. In a portable power station 104 having six battery modules 148, all of the battery modules 148 can receive the charging current at the same time. The number of battery modules 148 charged by the BMS 152 depends on the current capacity of the BMS 152 and can be less than the total number of battery modules 148. In one embodiment, the battery modules 148 are charged to 50% in approximately twenty-two minutes. When the battery modules 148 are charged to 50% capacity, the portable power station 104 is ready for use if the user determines that the portable power station 104 has sufficient capacity. Afterward, if the charge should continue, after each battery module 148 is charged to 50% capacity, the BMS 152 charges each battery module 148 to 80% capacity using a charging current. In one embodiment, the battery modules 148 are charged from 50% to 80% in approximately thirty-six minutes. When the battery modules 148 are charged to 80% capacity, the portable power station 104 is ready for use if the user determines that the portable power station 104 has sufficient capacity. Afterward, if the charge should continue, after each battery module 148 is charged to 80% capacity, the BMS 152 charges each battery module to 100% capacity using a charging current. In one embodiment, the battery modules 148 are charged from 80% to 100% in approximately nineteen minutes. In this way, the fast charging process provides the user with the opportunity to utilize the portable power station 104 without having to wait for each battery module 148 to be charged to 100% capacity.

[0052] In some embodiments, the portable power plant 104 is configured to boost the output voltage at the DC output connection 132 through a multi-stage voltage boosting process. Specifically, the BMS 152 uses the energy output unit 164 and the DC power source 216 to convert the DC voltage level of one battery module 148 from an initial voltage level to a first increased DC voltage level. In one embodiment, the BMS 152 includes a boost regulator to increase the DC voltage level. Thereafter, the BMS 152 uses the energy output unit 164 and the DC power source 216 to convert the first increased DC voltage level to a second increased DC voltage level. The first increased DC voltage level is greater than the initial voltage level, and the second increased DC voltage level is greater than the first increased DC voltage level. The second increased DC voltage level is at the expense of a reduction in the current capacity of the battery module 148. The second increased DC voltage is supplied to the load 108 through the DC output connection 132.

[0053] In another embodiment, instead of or in addition to the individually controllable and connectable battery modules 148, the portable power plant 104 includes individually controllable and connectable battery cells 180. In an exemplary embodiment, the portable power plant 104 includes twenty-five battery cells 180 that are individually controlled for optimal thermal management and other factors. The battery cells 180 are individually connectable to the load 108 and the charging unit 168. In operation, the ten battery cells 180 with the highest charge level and the lowest temperature (within the normal operating temperature range) are selected by the BMS 152 to supply electrical energy to the load 108. The individually controlled charging current can be supplied to the battery cells 180 that are not operatively connected to the load 108 until it is determined that the battery cells 180 are at an appropriate temperature for charging. The BMS 152 connects and disconnects the battery cells 180 from the load 108 so that ten of the twenty-five available battery cells 180 that are "best prepared" are operatively connected to the load 108 during use of the load 108.

[0054] While the present disclosure has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been presented and all changes, modifications and further applications that come within the spirit of the disclosure are desired to be protected.

Claims

1. A method of operating a portable power station, the portable power station comprising a plurality of battery modules and a battery management system operably connected to the plurality of battery modules, the method comprising: supplying, using the battery management system, a charging current generated from a mains power operably connected to an AC input connection of the portable power station to at least one first battery module of the plurality of battery modules to charge the at least one first battery module; electrically connecting, using the battery management system, at least one second battery module of the plurality of battery modules to a load to supply operating current to the load; and electrically disconnecting, using the battery management system, at least one third battery module of the plurality of battery modules from the charging current and the load to thermally manage the at least one third battery module, wherein the at least one first battery module, the at least one second battery module, and the at least one third battery module are located in an enclosure of the portable power station, and wherein charging the at least one first battery module, supplying the operating current from the at least one second battery module to the load, and thermally managing the at least one third battery module occur simultaneously.

2. The method of claim 1, further comprising: monitoring, using the battery management system, a temperature of the plurality of battery modules; determining when a monitored battery module has a temperature that exceeds a predetermined temperature; and electrically disconnecting, using the battery management system, the monitored battery module having a temperature that exceeds the predetermined temperature from the charging current and the load to cool the monitored battery module.

3. The method of claim 2, further comprising: monitoring a temperature of the at least one second battery module; determining that the temperature of the at least one second battery module exceeds the predetermined temperature; electrically disconnecting the at least one second battery module from the load to cool the at least one second battery module; electrically connecting at least one fourth battery module of the plurality of battery modules to the load to supply the operating current to the load, wherein the at least one fourth battery module has a temperature that is below the predetermined temperature.

4. The method of claim 3, further comprising: determining that the temperature of the at least one second battery module has dropped below the predetermined temperature; electrically disconnecting the at least one fourth battery module from the load; and electrically connecting the cooled at least one second battery module to the load to supply the operating current to the load.

5. The method of claim 1, further comprising: electrically disconnecting the plurality of battery modules from the load; and charging each battery module of the plurality of battery modules to 50% capacity using the charging current.

6. The method of claim 5, further comprising: ​ ​ after each of the plurality of battery modules is charged to 50% capacity, charging each of the plurality of battery modules to 80% capacity using the charging current.

7. The method of claim 6, further comprising: after each of the plurality of battery modules is charged to 80% capacity, charging each of the plurality of battery modules to 100% capacity using the charging current.

8. The method of claim 1, further comprising: determining a state of health of the plurality of battery modules; and identifying an unhealthy battery module of the plurality of battery modules based on a state of health of the unhealthy battery module compared to a predetermined state of health; removing the unhealthy battery module from the portable power plant; and inserting a healthy battery module into the portable power plant in place of the removed unhealthy battery module.

9. The method of claim 1, further comprising: electrically disconnecting the at least one second battery module of the plurality of battery modules from the load; and supplying another operating current generated by the mains power to the load.

10. The method of claim 9, further comprising: converting, using the battery management system, the mains power into a format suitable for generating another operating current.

11. The method of claim 1, further comprising: determining, using the battery management system, a maximum power output level of each battery module; determining, using the battery management system, a power demand of the load; and determining, using the battery management system, a predetermined number of the battery modules to connect to the load such that (i) the power demand of each battery module connected to the load is less than the maximum power output level, and (ii) the total power output level of the battery modules connected to the load is greater than the power demand of the load.

12. The method of claim 11, wherein, the predetermined number of battery modules are electrically connected to the load in parallel.

13. The method of claim 1, further comprising: electrically connecting the at least one second battery module to the load for a predetermined time period; electrically disconnecting the at least one second battery module from the load at the end of the predetermined time period; electrically connecting at least one other battery module of the plurality of battery modules to the load at the end of the predetermined time period.

14. The method of claim 1, further comprising: converting, using the battery management system, a DC voltage level of the at least one second battery module to a first increased DC voltage level; converting, using the battery management system, the first increased DC voltage level to a second increased DC voltage level; and supplying the second increased DC voltage level to the load, wherein the first increased DC voltage level is greater than the DC voltage level, and wherein the second increased DC voltage level is greater than the first increased DC voltage level.

15. A portable power plant for supplying electrical energy to a load, comprising: a housing having an AC input connection; a plurality of battery modules within the housing; and a battery management system operably connected to the plurality of battery modules, the battery management system configured to (i) electrically connect at least one first battery module of the plurality of battery modules to a charging current generated by the battery management system from a mains power coupled to the AC input connection to charge the at least one first battery module, (ii) electrically connect at least one second battery module of the plurality of battery modules to the load to supply operating current to the load, and (iii) electrically disconnect at least one third battery module of the plurality of battery modules from the mains power and the load to thermally manage the at least one third battery module, wherein charging the at least one first battery module, supplying the operating current to the load from the at least one second battery module, and thermally managing the at least one third battery module occur simultaneously.

16. The portable power station of claim 15, wherein, the battery management system further configured to (i) electrically disconnect the plurality of battery modules from the load, (ii) electrically connect the plurality of battery modules to the charging current to charge the battery modules, and (iii) charge each battery module of the plurality of battery modules to 50% capacity.

17. The portable power station of claim 16, wherein, the battery management system further configured to, after each battery module of the plurality of battery modules is charged to 50% capacity, charge each battery module of the plurality of battery modules to 80% capacity.

18. The portable power station of claim 17, wherein, the battery management system further configured to, after each battery module of the plurality of battery modules is charged to 80% capacity, charge each battery module of the plurality of battery modules to 100% capacity.

19. The portable power station of claim 15, wherein, the battery management system further configured to (i) monitor temperatures of the plurality of battery modules using the battery management system, (ii) determine when a monitored battery module has a temperature that exceeds a predetermined temperature, and (iii) disconnect, using the battery management system, the monitored battery module that has a temperature that exceeds the predetermined temperature from the charging current and the load to cool the monitored battery module.

20. The portable power station of claim 19, wherein: the battery management system further configured to (i) monitor the temperature of the at least one second battery module, (ii) determine that the temperature of the at least one second battery module exceeds the predetermined temperature, (iii) electrically disconnect the at least one second battery module from the load to cool the at least one second battery module, and (iv) electrically connect at least one fourth battery module of the plurality of battery modules to the load to supply the operating current to the load; and the at least one fourth battery module has a temperature that is below the predetermined temperature.

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