Module-based energy system capable of cascading and interconnected configuration and related methods

Abstract

A module-based energy system having a plurality of converter-source modules is provided. The converter-source modules may each include an energy source and a converter. The system may further include control circuits for the modules. The modules may be arranged in various ways to provide single-phase AC, multi-phase AC and / or DC outputs. Each module may be independently monitored and controlled.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Provisional Application Serial No. 62 / 826,158, filed on March 29, 2019, U.S. Provisional Application Serial No. 62 / 826,238, filed on March 29, 2019, and U.S. Provisional Application Serial No. 62 / 906,007, filed on September 25, 2019, all of which are incorporated herein by reference for all purposes. Technical Field

[0003] The subject matter described herein relates generally to module-based energy systems and modules for use therein, as well as systems, devices, and methods that facilitate connection and control of modules in module-based energy systems. Background Art

[0004] In many industries, energy systems with multiple energy sources or sinks are common. One example is the automotive industry. As evolved over the past century, today's automotive technology is characterized by the interaction of motors, mechanical elements, and electronics, among many other things. These are key components that affect vehicle performance and driver experience. Motors are of combustion or electric type, and it is usually found that each car has one motor, with the exception of cars with hybrid powertrains, which are characterized by a combination of an internal combustion engine with one or two motors, or performance-oriented electric vehicles equipped with two motors. In almost all cases, the rotational energy from (one or more) motors is delivered via a set of highly complex mechanical elements (such as clutches, transmissions, differentials, drive shafts, torque tubes, couplers, etc.). These parts control the torque conversion and power distribution of the wheels to a large extent, and are key elements that define the performance of the car. They also affect road handling. Over the years, individual automakers have highly optimized these mechanical parts to provide better performance, higher fuel efficiency, and ultimately provide differentiation in the market. On the control side, in addition to driver comfort such as entertainment, navigation and human machine interface elements, there are typically only a few specialized clusters of electronic hardware and embedded software that control / optimize the motor, clutch / transmission operation and lane keeping / handling.

[0005] An EV includes various electrical systems associated with the powertrain, which include, among other things, batteries, chargers, and motor controls. A brief overview of the current capabilities and shortcomings of these electrical systems is described below.

[0006] Conventional battery design

[0007] High voltage battery packs are typically organized as a series chain of lower voltage battery modules. Each such module further includes a set of individual battery cells connected in series and a simple embedded battery management system to regulate basic battery cell related characteristics such as state of charge and voltage. Electronic devices with more complex capabilities or some form of intelligent interconnectivity are lacking. Therefore, any monitoring or control functions are handled by a separate system, and there is no ability to monitor the health, state of charge, temperature, and other performance-impacting indicators of individual battery cells, if that system even exists elsewhere in the vehicle. There is also no ability to adjust the power consumption of each individual battery cell in any form. Some of the main consequences are: (1) the weakest battery cell constrains the overall performance of the entire battery pack, (2) the failure of any battery cell or module requires replacement of the entire battery pack, (3) the reliability and safety of the battery are greatly reduced, (4) the battery life is limited, (5) thermal management is difficult, (6) the battery pack is always operated below maximum capacity, and (7) the sudden influx of electrical energy derived from regenerative braking into the battery pack cannot be easily stored in the battery and will need to be dissipated via dump resistors.

[0008] Conventional charger design

[0009] The charging circuits are typically implemented in a separate onboard system. They stage the power coming from outside the EV in the form of an AC or DC signal, convert it to DC and feed it to the battery pack(s). The charging system monitors the voltage and current and typically supplies a steady constant feed. Given the design of the battery pack and typical charging circuits, there is little ability to customize the charging process for individual battery modules based on the health of the battery cells, performance characteristics, temperature, etc. Charging cycles are also typically long because the charging system and battery pack lack circuitry that would allow for pulse charging or other techniques that would optimize charge transfer or the total charge that can be achieved.

[0010] Conventional Motor Control Design

[0011] Conventional control contains a DC to DC conversion stage to adjust the battery pack voltage level to the bus voltage of the EV's electrical system. The motor is then in turn driven by a simple two-level multiphase converter that provides the required (one or more) AC signals to the motor. Traditionally, each motor is controlled by a separate controller that drives the motor in a 3-phase design. A dual-motor EV will require two controllers, while an EV using four in-wheel motors will require 4 individual controllers. Conventional controller designs also lack the ability to drive next-generation motors, such as switched reluctance motors (SRMs), which are characterized by a higher number of pole pieces. Adaptation will require a higher phase design, making the system more complex and ultimately unable to address electrical noise and drive performance issues, such as high torque ripple and acoustic noise.

[0012] Many of these deficiencies apply not only to automobiles, but also to other motor vehicles and, to some extent, to stationary applications. For these and other reasons, there exists a need for improved systems, devices and methods for energy systems for mobile and stationary applications. Summary of the invention

[0013] Provided herein are example embodiments of systems, devices, and methods for module-based energy systems that are widely associated with many applications. In many of these embodiments, a module-based energy system includes a plurality of modules, each of which includes at least an energy source and a converter. More complex configurations of each module are also disclosed. The modules of the system can be connected together in different arrangements of varying complexity to perform functions specific to the specific technical applications to which the system is applied. The system can be configured to repeatedly monitor the state information, at least one operating characteristic, or other parameter of each module during system use, evaluate the state of each module based on the monitored state information, operating characteristics, or other parameters, and independently control each module in an effort to achieve and / or maintain one or more desired goals, such as electrical performance, thermal performance, life, and the like. The control can occur to facilitate energy supply (e.g., discharge) and / or energy consumption (e.g., charging) from the system. Many example applications of these systems, devices, and methods are described.

[0014] In a number of example embodiments, at least one energy source of a module may include a capacitor (such as a supercapacitor or ultracapacitor), a battery, or a fuel cell unit.

[0015] In many example embodiments, the system may include at least two converter-source modules connected in a one-dimensional array or in a multi-dimensional array. The at least two one-dimensional arrays may be connected together, for example, directly or through one or more additional converter-source modules at different rows and columns. In such a configuration, an output voltage of any shape and frequency may be generated at the output of the module-based energy system as a superposition of the output voltages of the individual converter-source modules.

[0016] In many example embodiments, the system includes one or more interconnect modules capable of selectively powering one of two or more arrays of modules. The interconnect modules permit efficient energy exchange between arrays, and may also be used to compensate for imbalances in operating parameters (such as state of charge or temperature) that occur between different arrays. Thus, the interconnect modules may be used for inter-array balancing. If those arrays are dedicated to generating output waveforms at different phase angles, the interconnect modules may be used for inter-phase balancing.

[0017] Various interconnect architectures of example embodiments enable inter-array or inter-phase power management within a single module-based energy system (e.g., a battery pack) and inter-system power management between multiple module-based energy systems (e.g., battery packs), as well as connection of auxiliary loads to (one or more) systems and maintaining a uniform distribution of energy provided to those loads from all converter-source modules of such a system.

[0018] The various connection architectures of the example embodiments also enable control of power sharing between converter-source modules. Such control enables, for example, regulation of parameters (such as state of charge) of the energy sources of the converter-source modules to be balanced in real time and continuously during cycling and at rest, which facilitates utilization of the full capacity of each energy source, regardless of possible differences in their capacities. In addition, such control can be used to balance the temperature of the energy sources of the converter-source modules. For example, temperature balancing can increase the power capability of a system (e.g., a battery pack) and provide more uniform aging of the energy sources, regardless of their physical location within the system and differences in their thermal resistivity.

[0019] Other systems, devices, methods, features, and advantages of the subject matter described herein will be or will become apparent to one skilled in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this specification, be within the scope of the subject matter described herein, and be protected by the appended claims. In the absence of explicit recitation of features of the example embodiments in the claims, those features should in no way be construed as limiting the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The details of the subject matter set forth herein, both as to its structure and operation, may be apparent by studying the accompanying drawings, in which like reference numerals refer to like parts. The components in the various figures are not necessarily to scale, with emphasis instead being placed on illustrating the principles of the subject matter. Furthermore, all illustrations are intended to convey concepts, in which relative size, shape, and other detailed attributes may be illustrated schematically rather than literally or precisely.

[0021] Figure 1A , 1B and 1C are block diagrams depicting example embodiments of a module-based energy system.

[0022] Figure 2 is a block diagram depicting an example embodiment of a converter-source module (ConSource V1 ) having a local control device (LCD) connected to a master control device (MCD) according to an embodiment of the present disclosure.

[0023] Figure 3is a block diagram depicting another example embodiment of a converter-source module (ConSource V2) having an LCD connected to an MCD according to an embodiment of the present disclosure.

[0024] Figure 4 is a block diagram depicting another example embodiment of a converter-source module (ConSource V3) having an LCD and optional auxiliary load connected to an MCD according to an embodiment of the present disclosure.

[0025] Figure 5A The invention is a diagram illustrating an embodiment of the present invention. Figure 2 Schematic diagram of an example embodiment of a converter (converter V1 ) is shown in .

[0026] Figure 5B The invention is a diagram illustrating an embodiment of the present invention. Figure 2 and 3 Schematic diagram of an example embodiment of a converter (converter V2) shown in FIG.

[0027] Fig. 6A , 6B 6C are diagrams depicting example embodiments of energy storage elements used as the energy source shown in FIGS. 1 , 2 , and 3 according to embodiments of the present disclosure.

[0028] Fig. 7A , 7B 7C are schematic diagrams depicting example embodiments used as energy buffers as shown in FIGS. 1 , 2 , and 3 , according to embodiments of the present disclosure.

[0029] Fig. 8A , 8B 8C, 8D, 8E and 8F are diagrams showing the use of Figure 3 FIG. 5 is a diagram of an example embodiment of an energy source 2 shown in FIG.

[0030] Fig. 9 is a graph depicting the output voltage of an example converter according to an embodiment of the present disclosure.

[0031] Fig.10 is a graph depicting output voltage of an example module-based energy storage system having six example converter-source modules according to an embodiment of the disclosure.

[0032] Fig.11 The invention is a diagram for describing an embodiment of the present invention. Figure 3 A block diagram of an example embodiment of power flow management of an example converter-source module (ConSource V2) shown in FIG.

[0033] Fig. 12A and 12B It depicts Figure 3Graph of example waveforms for the converter-source (ConSource V2) module shown in , where converter V2 provides a secondary function of reducing second-order current harmonics.

[0034] Fig.13 The invention is a diagram illustrating an embodiment of the present invention. Figure 4 A block diagram of an example embodiment of power flow management of a converter-source (ConSource V3) module is shown in FIG.

[0035] Fig.14A , 14B , 14C, and 14D are graphs depicting example embodiments of pulse width modulation suitable for use with an example embodiment of a module based energy system.

[0036] Fig.15 is a schematic diagram depicting an example one-dimensional array of example converter-source modules connected according to example embodiments of the present disclosure.

[0037] Fig.16 is a schematic diagram depicting an example two-dimensional array of example converter-source modules connected according to example embodiments of the present disclosure.

[0038] Fig.17 is a schematic diagram depicting another example two-dimensional array of example converter-source modules connected according to example embodiments of the present disclosure.

[0039] Fig.18 is a schematic diagram depicting an example system having a plurality of example converter-source modules connected in a three-dimensional array according to an example embodiment of the present disclosure.

[0040] Fig.19 is a schematic diagram depicting another example system having a plurality of example converter-source modules connected in a three-dimensional array according to an example embodiment of the present disclosure.

[0041] Fig. 20 is a schematic diagram depicting another example system having a plurality of example converter-source modules connected in a three-dimensional array according to an example embodiment of the present disclosure.

[0042] Fig.21 is a schematic diagram depicting an example system having a plurality of example converter-source modules connected in a multi-dimensional array according to an example embodiment of the present disclosure.

[0043] Fig. 22 is a schematic diagram depicting an example system having a plurality of example converter-source modules connected in a three-dimensional array and connected to an electric machine according to an example embodiment of the present disclosure.

[0044] Fig.23is a schematic diagram depicting another example system having a plurality of example converter-source modules connected in a three-dimensional array and connected to an electric machine according to an example embodiment of the present disclosure.

[0045] Fig.24 is a schematic diagram depicting another example system having a plurality of example converter-source modules connected in a three-dimensional array and connected to a motor and an auxiliary load according to an example embodiment of the present disclosure.

[0046] Fig.25 is a schematic diagram depicting another example system having a plurality of example converter-source modules connected in a three-dimensional array and connected to a motor and an auxiliary load according to an example embodiment of the present disclosure.

[0047] Fig.26 is a schematic diagram depicting another example system having a plurality of example converter-source modules connected in a six-dimensional array and connected to a six-phase electric machine and an auxiliary load according to an example embodiment of the present disclosure.

[0048] Fig.27A and 27B is a schematic diagram depicting an additional example system having a plurality of example converter-source modules connected in a three-dimensional array and connected to a plurality of three-phase motors and auxiliary loads according to an example embodiment of the present disclosure.

[0049] Fig.28 is a schematic diagram depicting another example system having a plurality of example converter-source modules connected in a three-dimensional array and connected to a three-phase open winding motor and an auxiliary load according to an example embodiment of the present disclosure.

[0050] Fig.29 A schematic diagram depicting another example system having a plurality of example converter-source modules connected in a three-dimensional array and connected to two three-phase open winding motors and an auxiliary load is illustrated according to an example embodiment of the present disclosure.

[0051] Fig.30 is a schematic diagram depicting an example embodiment of a single-phase balancing controller for use with example embodiments of the present disclosure.

[0052] Fig.31 Depicted is a phasor diagram for voltage sharing control of an example single phase system for use with example embodiments of the present disclosure.

[0053] Fig.32 Depicted is a schematic diagram depicting an example embodiment of a single phase balancing controller for use with example embodiments of the present disclosure.

[0054] Fig.33A and33B Depicted are phasor diagrams for voltage balancing control of a three-phase structure for (A) intra-phase balancing only and (B) intra-phase and inter-phase balancing.

[0055] Fig.34A and 34B Depicted is a phasor diagram of a three-phase structure with interconnected modules (or common modules) with voltage balancing control with intra-phase and inter-phase balance through (A) common modules and (B) common modules and neutral point offset.

[0056] Fig.35A and 35B Depicted are phasor diagrams of voltage balancing control for a four-phase system with intra-phase and inter-phase balance utilizing (A) neutral point offset and (B) interconnection modules and neutral point offset.

[0057] Fig.36A and 36B Depicted are phasor diagrams of voltage balancing control for a five-phase system with intra-phase and inter-phase balance utilizing (A) neutral point offset and (B) interconnection module and neutral point offset.

[0058] Fig.37A and 37B Depicted are phasor diagrams of voltage balancing control for a six-phase system with intra-phase and inter-phase balance utilizing (A) neutral point offset and (B) interconnection module and neutral point offset.

[0059] Fig.38A and 38B Depicted is a phasor diagram of voltage balancing control with intra-phase and inter-phase balance for the example system shown in FIG. 27 via (A) interconnect modules and (B) interconnect modules and neutral point offset.

[0060] Fig.39A and 39B Depicted Fig.28 The system shown in FIG. 1 is a phasor diagram of voltage balancing control with intra-phase and inter-phase balance through (A) interconnection modules and (B) interconnection modules and neutral point offset.

[0061] Fig.40A and 40B Depicted Fig.29 The system shown in FIG. 1 is a phasor diagram of voltage balancing control with intra-phase and inter-phase balance through (A) interconnection modules and (B) interconnection modules and neutral point offset.

[0062] Figures 41A-41F are block diagrams and schematic diagrams depicting example embodiments of energy supply systems having interconnected modules.

[0063] Figures 42A-42B is a flow chart depicting an example embodiment of a method of performing phase balancing using an interconnect module.

[0064] Figures 43A-43Cis a block diagram depicting an example embodiment of a converter-source module.

[0065] Fig.44A and 44B is a schematic diagram depicting an example embodiment of components of a converter-source module mounted on one or more substrates. DETAILED DESCRIPTION

[0066] Before describing the present subject matter in detail, it is to be understood that the present disclosure is not limited to the particular embodiments described, as this may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting, as the scope of the present disclosure will be limited only by the appended claims.

[0067] Example embodiments of module-based energy systems are described herein, as follows: example embodiments of devices, circuits, software, and components within such systems; example embodiments of methods of operating and using such systems; and example embodiments of applications (e.g., devices, machines, grids, sites, structures, environments, etc.) in which such systems may be implemented or incorporated or utilized with such systems. In many cases, these applications may be classified as mobile applications or fixed applications.

[0068] Application Examples

[0069] Mobile applications are generally such applications in which a module-based energy system is located on or within an entity and stores and provides electrical energy to move or assist in moving the entity by converting it into power through a motor. Examples of mobile entities that can be used with the embodiments disclosed herein include, but are not limited to: electric and / or hybrid entities that are on or below land, on or below the sea, above land or above the sea, and out of contact with land or sea (e.g., flying or hovering in the air) or moving through outer space. Examples of mobile entities that can be used with the embodiments disclosed herein include, but are not limited to: vehicles, trains, ships, boats, spacecraft, and spacecraft. Examples of mobile vehicles that can be used with the embodiments disclosed herein include, but are not limited to: mobile vehicles with only one wheel or track, mobile vehicles with only two wheels or tracks, mobile vehicles with only three wheels or tracks, mobile vehicles with only four wheels or tracks, and mobile vehicles with five or more wheels or tracks. Examples of mobile entities that may be used with the embodiments disclosed herein include, but are not limited to, automobiles, buses, trucks, motorcycles, scooters, industrial vehicles, mining vehicles, aircraft (e.g., airplanes, helicopters, drones, etc.), marine vessels (e.g., commercial shipping vessels, ships, yachts, boats, or other watercraft), submarines, locomotives or rail-based vehicles (e.g., trains, etc.), military vehicles, spacecraft, and satellites.

[0070] Fixed applications are generally applications other than mobile applications. Generally, in fixed applications, module-based energy systems reside in static locations while providing electrical energy for consumption by one or more other entities. Examples of fixed applications in which the embodiments disclosed herein may be used or used with them include, but are not limited to: energy systems used or used in one or more residential structures or places, energy systems used or used in one or more industrial structures or places, energy systems used or used in one or more commercial structures or places, energy systems used or used in one or more government structures or places (including both military and non-military uses), and systems that convert solar energy, wind energy, geothermal energy, fossil fuels, or nuclear reactions into electricity for storage. Examples of fixed applications in which the embodiments disclosed herein may be used or used with them include, but are not limited to: energy systems (e.g., charging stations) for charging the above-mentioned mobile applications. Other examples of fixed applications in which the embodiments disclosed herein may be used or used with them include, but are not limited to: data center storage systems, power grids, or microgrids. Fixed energy systems may be used in storage or non-storage roles.

[0071] When describing embodiments herein, reference may be made to a particular mobile application (e.g., an electric vehicle (EV)) or a stationary application (e.g., an electrical grid). Such reference is for ease of explanation and does not imply that a particular embodiment is limited to use with that particular mobile or stationary application. Embodiments of systems for providing power to electric machines may be used in both mobile and stationary applications. Although certain configurations may be more suitable for some applications than others, all example embodiments disclosed herein are capable of use in both mobile and stationary applications unless otherwise noted.

[0072] Example Embodiment of a Module-Based Energy System

[0073] Figure 1A An example embodiment of a module-based energy system 100 is depicted. Here, the system 100 includes a control circuit 102 that is communicatively coupled to N converter-source modules 108-1 through 108-N via communication paths or links 106-1 through 106-N, respectively. In these embodiments, any number of two or more converter-source modules 108 may be used (e.g., N is greater than or equal to two). The converter-source modules 108 - referred to herein as "ConSource" modules or modules 108 - may be connected to each other in a variety of ways, such as will be described with reference to FIG. Figure 15-29 For ease of explanation, Figures 1A-1C, the modules 108 are shown connected in series, or as a one-dimensional array, where the Nth module 108 is coupled to a load 101. The load 101 is an electrical load to which power is output when the system 100 is used to provide power. The load 101 can be any type of load, including but not limited to a motor or an electrical grid. For charging, in addition to or instead of the load 101, the module 108 can be coupled to a charging source (not shown). As will be described in more detail herein, the system 100 can be configured to supply multiple loads 101, including both primary loads and auxiliary loads.

[0074] exist Figure 1A In an embodiment of the present invention, the control circuit 102 is configured to control one or more modules 108 based on status information received from the same or different one or more modules 108. Control may also be based on one or more other factors, such as the requirements of the load 101. In many embodiments, the aspect controlled is the output power of each module 108 over time; however, other aspects may be controlled instead of or in addition to output power.

[0075] The load requirement information 109 may be received by the control circuit 102 via the communication path or link 107. The load requirement information 109 may inform the control circuit 102 about the needs of the load 101 at any particular time. In some example embodiments, the load requirement information 109 may take the form of one or more analog or digital control signal waveforms (e.g., a different control signal waveform for each phase), such as may be provided by a controller for a mobile entity (e.g., an electronic control unit (ECU) or main control unit (MCU) of an EV responsible for one or more other functions (e.g., motor control, driver interface control, traction control, etc.)) or a controller for an electric grid or other stationary energy storage system. As an alternative to or in addition to information supplied by another controller, in some embodiments, the load requirement information 109 may include load measurements (e.g., voltage, current) taken by one or more sensors of the system 100, where those measurements are supplied back to the control circuit 102 in a feedback loop for maintaining certain power supply conditions.

[0076] In many embodiments, the status information of each module 108 in the system 100 will be transmitted to the control circuit 102, and the control circuit 102 will independently control each module 108-1...108-N based on the status information. Other variations are possible. For example, control of a particular module 108 (or a subset of modules 108) can be based on the status information of the particular module 108 (or a subset of ConSource modules 108), based on the status information of a different module 108 that is not the particular module 108 (or a subset of modules 108), based on the status information of all modules 108 other than the particular module 108 (or a subset of modules 108), based on the status information of the particular module 108 (or a subset of modules 108) and the status information of at least one other module 108 that is not the particular module 108 (or a subset of modules 108), or based on the status information of all modules 108 in the system 100. This includes systems 100 that supply multiple loads or motors and have modules 108 arranged in multiple packages.

[0077] As will be described herein, the state information may be information about one or more aspects of each module 108. The state information may be an operating characteristic or other parameter. Types of state information include, but are not limited to, the following aspects of the module 108 or its components: state of charge (SOC) (e.g., the charge level of the energy source relative to its capacity, such as a fraction or percentage), state of health (SOH) (e.g., a quality factor of the condition of the energy source compared to its ideal condition), capacity (Q), temperature (T), voltage (V), current (I), or the presence or absence of a fault. Each module 108 includes one or more sensors or other measuring elements for collecting sensing or measurement signals or data that constitute or can be converted into state information. A separate sensor is not required to collect each type of state information, as more than one type of state information may be sensed or measured using a single sensor, or otherwise determined by an algorithm without the need for additional sensors.

[0078] Figure 1BAnother example embodiment of the system 100 is depicted. Here, the control circuit 102 is implemented as a master control device 112 that is communicatively coupled to N different local control devices 114-1 to 114-N via communication paths or links 115-1 to 115-N, respectively. Each local control device 114-1 to 114-N is communicatively coupled to one converter-source module 108-1 to 108-N via communication paths or links 116-1 to 116-N, respectively, such that there is a 1:1 relationship between the local control devices 114 and the converter-source modules 108. The master control device 112 can be communicatively coupled to all local control devices 114 in the system, regardless of whether those local control devices 114 are powering the same load. For example, one master control device 112 can receive information and send information to local control devices 114 of multiple different subsystems and packages.

[0079] Figure 1C Another example embodiment of the system 100 is depicted. Here, the master control device 112 is communicatively coupled to M different local control devices 114-1 through 114-M via communication paths or links 115-1 through 115-M, respectively. The local control devices 114 may be coupled to and control two or more converter-source modules 108. In the example shown here, each local control device 114 is communicatively coupled to two converter-source modules 108, such that the M local control devices 114-1 through 114-M are coupled to 2M converter-source modules 108-1 through 108-2M, respectively, via communication paths or links 116-1 through 116-2M.

[0080] Communication paths or links 106, 107, 115, and 116 can each be a wired or wireless communication path or link that transmits data or information bidirectionally in parallel or serial manner. Data can be transmitted in a standard or custom format. In some (e.g., automotive) applications, communication path or link 115 can be configured to transmit data according to the FlexRay or CAN protocol.

[0081] In reference Figure 1B and 1CIn the described embodiment, the local control device 114 receives status information from each module 108, or determines status information based on sensed or measured signals or data received from each module 108, and transmits the information to the master control device 112. In some embodiments, the local control device 114 transmits the measured or sensed data to the master control device 112, which then determines the status information through an algorithm based on the raw data. The master control device 112 can then use the status information about all modules 108 to make control determinations accordingly. The control determinations can take the form of instructions, commands, or other information (such as the modulation index described below) that can be interpreted or utilized by the local control device 114 to maintain or adjust the operation or contribution of the module 108.

[0082] For example, with respect to SOC, if, when reading the SOC measurements of all modules 108, the master control device 112 makes an assessment that a first module 108 is operating at a relatively lower SOC than other modules 108 powering one phase of the system 100, the master control device 112 may instruct the first module 108 to reduce its power output, and may instruct one or more other modules 108 to increase the power output (one or more) in the phase to compensate. This should cause the SOC of the other modules 108 to decrease faster than the SOC of the first module 108, and thereby converge to an equilibrium condition. With respect to temperature, if, when reading the temperature measurements of all modules 108, the master control device 112 makes an assessment that a first module 108 is operating at a relatively higher temperature than other modules 108 powering one phase in the system 100, the master control device 112 may instruct the first module 108 to reduce its power output, and may instruct one or more other modules 108 to increase the power output (one or more) in the phase to compensate. This should cause the temperature of the first module 108 to approach the temperatures of the other modules 108 (by cooling the first module 108 and / or heating the other modules 108 ), and thus converge to an equilibrium condition.

[0083] The master control device 112 may receive status information indicating one or more of the following conditions under which a particular module 108 (or a component thereof) is operating relative to one or more other modules 108 in the system 100: having a relatively lower SOC, having a relatively lower SOH, having a relatively lower capacity, having a relatively lower voltage, having a relatively lower current, having a relatively higher temperature, or having a fault. In such an example, the master control device 112 may output control information that causes the power output of the particular module 108 to be reduced (or in some cases, increased depending on the conditions). In this way, the power output of a module 108 operating at, for example, a higher temperature may be reduced in order to cause the temperature of the module 108 to converge toward the temperature of one or more other modules 108.

[0084] In other embodiments, the determination of whether to adjust the operation of a particular module 108 may be made by comparing the status information to a predetermined threshold, limit, or condition, and not necessarily by comparing the status of other modules 108. The predetermined threshold, limit, or condition may be a static threshold, limit, or condition, such as those set by the manufacturer that do not change during use. The predetermined threshold, limit, or condition may be a dynamic threshold, limit, or condition that is permitted to change or does change during use. For example, if the status information of a module 108 indicates that it is operating in violation of (e.g., above or below) a predetermined threshold or limit, or operating outside a predetermined range of acceptable operating conditions, the master control device 112 may adjust the operation of the module 108. Similarly, if the status information of a module 108 indicates the presence of an actual or potential fault (e.g., an alarm or warning), or indicates the absence or removal of an actual or potential fault, the master control device 112 may adjust the operation of the module 108. Examples of faults include, but are not limited to, an actual fault of a component, a potential fault of a component, a short circuit or other overcurrent condition, an open circuit, an overvoltage condition, a failure to receive communications, receiving corrupted data, and the like.

[0085] The local control device 114 can receive, process and transmit: signals from various sensors of the module 108 (e.g., temperature, voltage and current sensors); switch (e.g., trigger) and fault signals to and from the semiconductor switches; voltages of the basic battery cells of the energy storage and buffer elements; and other signals. The local control device 114 can communicate with the main control device 112 and transmit corresponding control signals to and from the main control device 112.

[0086] In this manner, the master control device 112 can control the modules 108 within the system 100 to achieve a desired goal or converge toward a desired goal. For example, the goal can be the operation of all modules 108 at the same or similar level relative to each other, or within predetermined threshold limits or conditions. This process is also referred to as balancing or seeking to achieve a balance in the operation or operating characteristics of the modules 108. The term "balance" as used herein does not require absolute equality between the modules 108 or their components, but is used in a broad sense to convey to one of ordinary skill in the art that the operation of the system 100 can be used to actively reduce operational differences between the modules 108 that would otherwise exist.

[0087] Return to reference Figure 1A , the control circuit 102 can be configured to operate and perform control using software (instructions stored in memory that can be executed by the processing circuit), hardware, or a combination thereof. As shown here, the control circuit 102 may include a processing circuit 120 and a memory 122. Example implementations of the processing circuit 120 and the memory 122 are further described below. The communication path or link 106 may also include a wired power supply to supply operating power directly to the control circuit 102 from one or more converter-source modules 108. In some embodiments, the power for the control circuit 102 is supplied only from one or more modules 108.

[0088] refer to Figure 1B-1C , the master control device 112 and the local control device 114 can be similarly configured to operate and perform control using software (instructions stored in memory that can be executed by processing circuits), hardware, or a combination thereof, and each can include a processing circuit 120 and a memory 122, as shown here. Example implementations of the processing circuit 120 and the memory 122 are further described below. The communication path or link 116 can also include a wired power supply to supply operating power directly to the local control device 114 from one or more modules 108. In some embodiments, the operating power for each local control device 114 is supplied only by the one or more modules 108 to which the local control device 114 is connected via the path 116. The operating power of the master control device 112 can be supplied indirectly from one or more modules 108 (e.g., such as through the power network of the car).

[0089] In some embodiments, control circuitry 102 may comprise a single control device for the entire system 100. In other embodiments, control circuitry may be distributed among local control devices 114 associated with modules 108 such that a separate master control device 112 is not necessary and may be omitted from system 100.

[0090] In some embodiments, control of the system 100 may be distributed between control circuitry 102 that is dedicated or local to the system 100 and control circuitry that is shared with other parts of the application. For example, the master control device 112 may be implemented as part of a mobile or stationary controller that provides load requirement information 109 to the system 100 (e.g., an ECU or MCU). The control circuitry 102 may have a communication interface for communicating with another control device of the overall mobile or stationary application. For example, in an automotive application, the control circuitry 102 (e.g., the master control device 112) may output data or information about the system 100 to the ECU or MCU of the vehicle.

[0091] Example Embodiment of a Converter-Source Module within a Module-Based System

[0092] Figure 2-4 Describes Figure 1B 100, wherein each module 108 has a local control device 114. Unless otherwise indicated, Figure 2-4 The embodiments and any and all other embodiments described herein may be based on Figures 1A-1C configuration to achieve this.

[0093] The ConSource module 108 may be implemented as a voltage converter or a current converter. For ease of description, the embodiments described herein are done with reference to a voltage converter, although the embodiments may alternatively be configured as a current converter.

[0094] Figure 2 1 is a block diagram depicting an example embodiment of a ConSource module 108A within a system 100. This embodiment of the ConSource module 108A may be referred to herein as version 1 (ConSource V1) of an example ConSource module, and is an example of one type of converter-source module 108. Also shown are a local control device 114 (LCD) and a master control device 112 (MCD). ConSource V1 108A is communicatively coupled to LCD 114, which in turn is communicatively coupled to MCD 112.

[0095] ConSource V1 108A includes an energy source 202 (Energy Source 1), which may include one or more energy storage elements. Energy Source 1 may be, for example, one of the following, but is not limited to: a high energy density (HED) capacitor, such as a supercapacitor or ultracapacitor 600 ( Fig. 6A ); A battery module 610 including at least one battery cell or a plurality of battery cells connected in series and / or in parallel ( Figure 6B); or fuel, fuel cell unit or fuel cell unit module 620 ( Figure 6C ). As opposed to solid dielectrics, HED capacitor 600 can utilize double layer capacitance and, in addition to higher capacitance, can also have an energy density 10 to 100 times (or more) that of ordinary electrolytic capacitors. Battery Energy Sources.

[0096] Energy can be input and output through a first node (e.g., a positive node) out1 and a second node (e.g., a negative node) out2. The outputs out1 and out2 of the energy source 1 can be connected to input terminals in1 and in2 of an energy buffer 204, respectively. The energy buffer 204 can include, for example, one of the following elements and topologies, but is not limited to the following elements and topologies, which are based on: electrolytic and / or film capacitors CEB 700 ( Fig. 7A ); a Z source network 710 formed by two inductors LEB1 and LEB2 and two electrolytic and / or film capacitors CEB1 and CEB2 ( Figure 7B ); a quasi-Z source network 720 formed by two inductors LEB1 and LEB2, two electrolytic and / or film capacitors CEB1 and CEB2, and a diode DEB ( Figure 7C ). The selection of the specific topology and components of the energy buffer depends on the maximum permissible amplitude of the high frequency voltage ripples at the energy buffer output terminals out1 and out 2. These ripples may degrade the performance of the ConSource module 108, so they can be efficiently buffered by designing appropriate components and topology as its basis.

[0097] The outputs out1 and out2 of the energy buffer 204 are connected to the inputs in1 and in2 of the converter V1 , respectively. Figure 5A A schematic representation of an example embodiment of a converter V1 206 is shown in FIG. The converter V1 206 may include a switch circuit 207 configured to apply at least three different voltages (based on the line voltage V DCL ):+V DCL , -V DCL and zero (e.g., a short circuit condition). The switch circuit 207 can also be configured to prevent current from flowing across out1 and out2 (e.g., an open circuit condition). The switch circuit 207 can be configured in many different ways in many different switch types. Example switch types include, but are not limited to, semiconductor switches such as metal oxide semiconductor field effect transistors or MOSFETs (e.g., Figure 5A), insulated gate bipolar transistors (IGBTs), or gallium nitride (GaN) transistors. The semiconductor switches can be operated at a relatively high switching frequency, thereby permitting the converter V1 to operate in a pulse width modulation mode when desired and respond to control commands in relatively short time intervals. This can provide high output voltage regulation tolerance and fast dynamic behavior in transient mode. The switch circuit 207 can be controlled by one or more control or switching signals (not shown) generated by the control circuit 102 (e.g., MCD 112 or LCD 114).

[0098] In many embodiments, the switch circuit 207 may include at least four independently controllable switches S3, S4, S5, S6, which may be configured as an H-bridge. In this embodiment, the converter V1 206 converts the DC line voltage V to V1 through different combinations of the switches S3, S4, S5, S6. DCL Connected between its terminals in1 and in2 to its output terminals out1 and out2, thus generating three different voltage outputs +V DCL , 0, and –V DCL In order to obtain +V DCL , switches S3 and S6 are turned on, and –V DCL This can be achieved by turning on switches S4 and S5. By turning on S3 and S5 or S4 and S6, the output voltage is set to zero (eg, short circuit) or to a reference voltage.

[0099] The control or switching signals (input path not shown) of the semiconductor switches S3, S4, S5, S6 may depend on the LCD and MCD (eg Figure 2 The flexibility and requirements of the control technique employed in the converter V1 are generated in different ways. One approach is to use a pulse width modulation (PWM) technique, such as space vector pulse width modulation SVPWM or sinusoidal pulse width modulation SPWM or a variation thereof, to generate the output voltage of the converter V1. Fig. 9 An example of an output voltage waveform 900 of the converter V1 is shown in . The modulation method also depends on which version of the system 100 it is applied to, and one possible modulation solution will be further presented herein as an example.

[0100] In some embodiments using PWM, the LCD (rather than the MCD) generates the switching signals for the switches in the ConSource module, although PWM embodiments are not limited in this regard. In some embodiments, such as those using hysteresis, the generation of the switching signals may be performed by the MCD. Figure 2The LCD 114 shown in FIG. 1 can be connected to the ConSource V1 108A via a set of diagnostic, measurement, protection and control signal lines and can perform one or more of three main functions. The first function is the management of the Energy Source 1. The second function is the protection of the energy buffer, and more specifically, the protection of its components from overcurrent, overvoltage and high temperature conditions. The third function is the control and protection of the converter V1 206.

[0101] In one exemplary embodiment, the functions of the Energy Source 1 for the ConSource V1 module 108A managed by the LCD 114 are as follows. The LCD 114 receives measurement signals VES1, TES1, IES1, which are: VES1 - voltage of at least one, preferably all, of the Energy Source 1, or voltage of a group of elementary components, such as, for example and without limitation, battery cells (individually or connected in series and / or in parallel), supercapacitor cells (individually or connected in series and / or in parallel); TES1 - temperature of at least one, preferably all, of the Energy Source 1, or temperature of a group of elementary components; IES1 - output current of the Energy Source 1. Based on these measurement signals, the LCD 114 can perform one or more of the following: calculation or determination of the real capacity, actual state of charge (SOC) and state of health (SOH) of the elementary component or group of elementary components; setting of warning or alarm signals based on the measured and / or calculated data; and / or transmitting corresponding signals to the MCD 112.

[0102] In one exemplary embodiment, the LCD protection function for the energy buffer 204 of the ConSource V1 module 108A is as follows. The LCD 114 receives measurement signals VEB, TEB, IEB, which are: VEB - the voltage of at least one main component of the energy buffer 204, such as and not limited to capacitor CEB or capacitors CEB1, CEB2 (see Figures 7A-7C ); TEB - temperature of at least one component of the energy buffer 204; and / or IEB - current through at least one component of the energy buffer 204. Based on these measurement signals, the LCD 114 can perform the following: set a warning or alarm signal based on the measurement data; and / or transmit a corresponding warning or alarm signal to the MCD 112.

[0103] In one example embodiment, the control and protection of the converter V1 206 of the ConSource V1 module 108A by the LCD 114 functions as follows. The LCD may receive a command signal from the MCD via path 115 (e.g., via FlexRay or CAN), which in some embodiments may be a modulation reference signal and an enable signal, or a reference signal and a modulation index, which may be used with a pulse width modulation technique in the LCD to generate control signals for semiconductor switches S3, S4, S5, S6. The current feedback signal IOUT ( Figure 2 ) can be connected to the switch driver circuit (not shown) from converter V1 206 Figure 2 The LCD can use one or more signals F (not shown) for overcurrent protection, which can carry information about the fault status of all switches in the converter V1 (e.g., short circuit or open circuit failure mode). Based on this data, the LCD can make a decision about which switch signal combination will be applied to the corresponding semiconductor switches S3, S4, S5, S6 to bypass or disconnect the converter V1 and the entire ConSource V1 module 108A from the system 100. (The switch signal of a specific switch can turn the switch on or off.).

[0104] Figure 3 is a block diagram depicting another example embodiment of a ConSource module 108B, which may be referred to herein as version 2 of the ConSource module (ConSource V2), and is an example of one type of converter-source module 108. ConSource V2 108B is communicatively coupled with LCD 114, which in turn is communicatively coupled with MCD 112.

[0105] In this embodiment, ConSource V2 108B is in a dual energy source configuration with a primary energy source 1 202 and a secondary energy source 2 304. As with ConSource V1 108A, Energy Source 1 may be or include a primary energy source 1 202 and a secondary energy source 2 304. Figures 6A-6C Any examples described or otherwise.

[0106] The outputs out1 and out2 of Energy Source 1 202 may be connected to input terminals in1 and in2 of Energy Buffer 204. As with ConSource V1 108A, Energy Buffer 204 may be or include a reference Figures 7A-7C Any example described or other examples. Outputs out1 and out2 of energy buffer 204 are connected to inputs in1 and in3 of converter V2 308, respectively.

[0107] The output out2 of the energy buffer 204 may also be connected to the output out2 of the energy source 2 304. Another output out1 of the energy source 2 may be connected to the input in2 of the converter V2 308. The energy source 2 may include, for example, one of the following storage elements, but is not limited thereto, such as: an electrolytic and / or film capacitor CEB 800 ( Fig. 8A ); High Energy Density (HED) Capacitor 600 ( Figure 8B ); a battery or battery module 610, comprising at least one battery cell or a plurality of battery cells connected in series and / or in parallel ( Figure 8C ); electrolytic and / or film capacitor CEB 800 connected in parallel with the high energy density capacitor 600 ( Fig.8D ); electrolytic and / or film capacitor CEB 800 connected in parallel with the battery module 610 ( Fig. 8E ); electrolytic and / or film capacitor CEB 800 connected in parallel with the high energy density capacitor 600 and the battery module 610 ( Fig.8F ).

[0108] Figure 5B A simplified schematic representation of an example embodiment of a converter V2 308 is shown in FIG. Here, the converter V2 308 includes a switching circuit 207 (as described with respect to FIG. Figure 5A ) and switch circuit 208. Switch circuit 208 may be configured in any arrangement and with any switch type that selectively switches in2 (via L C ) is coupled to in1 or in3. The switch circuit 208 can also be configured to prevent current from flowing from in1 and in3 through in2 (i.e., isolate in2). The switch circuit 208 can be configured in any switch type described herein (e.g., semiconductor MOSFET, IGBT, GaN transistor, or other). The semiconductor switch can be operated at a high switching frequency, thereby permitting the converter V2 308 to operate in pulse width modulation mode when required and respond to control commands in short time intervals, thereby providing high output voltage regulation tolerance and fast dynamic behavior in transient mode.

[0109] In this embodiment, the switch circuit 208 includes two independently controllable switches S1 and S2 and can generate two different voltages at node 1, namely +VDCL and 0, with reference to the input In3, which can be at virtual zero potential. C Connected between input In2 and node 1. The output out1 of energy source 2 is connected to the coupled inductor L at the input In 3 of converter V2 308 C The current consumed from or generated to the energy source 2 304 can be adjusted by adjusting the coupled inductor LC The control signal input paths of switches S1 and S2 are not shown.

[0110] In this embodiment, the switch circuit 207 is similar to Figure 5A , and includes four switches S3, S4, S5, S6, which connect the DC line voltage V between the terminals in1 and in2 through different combinations of the switches S3, S4, S5, S6. DCL Connected to the output terminals out1 and out2, it can generate three different voltage outputs, namely +V DCL , 0 (or short-circuit condition), and –V DCL . To obtain a +VDCL voltage between out1 and out2, switches S3 and S6 are turned on, while a –VDCL voltage between out1 and out2 can be obtained by turning on switches S4 and S5. By turning on S3 and S5 or S4 and S6, the output voltage is set to zero or a reference potential. As with semiconductor switches S1 and S2, control of semiconductor switches S3, S4, S5, S6 can be performed using various PWM or hysteresis techniques or other techniques described herein. The control signal input paths of switches S3, S4, S5, S6 are not shown.

[0111] In this ConSource V2 module 108B example, Energy Source 1 202 acts as the primary energy source and thus supplies the average power required by the load. Energy Source 2 304 may be a secondary energy source that has the function of assisting Energy Source 1 by providing additional power at load power peaks or absorbing excess power.

[0112] Fig.10 An output voltage waveform 1000 from an example module-based energy storage system having six example converter-source modules 108 is shown.

[0113] Fig.11 1 is a block diagram depicting an example embodiment of power flow management 1100 between two energy sources (Energy Source 1 202 and Energy Source 2 304) and a load of an example embodiment of a ConSource V2 module 108B. The load may be, for example, but not limited to, a single phase of an electrical grid or an electric vehicle motor. This embodiment allows for complete decoupling between the electrical characteristics (terminal voltage and current) of each energy source and the electrical characteristics of the load 1102.

[0114] In these embodiments, power flow controller 1 1110 and power flow controller 2 1120 may be discrete control devices, separate from LCD 114 and MCD 112, and may be implemented as software within the LCD, may be implemented as hardware within the LCD, or may be implemented as a combination of hardware and software within the LCD. In some embodiments, the functionality of power flow controller 1 1110 and power flow controller 2 1120 may be shared or distributed between LCD 114 and MCD 112.

[0115] The power flow controller 1 1110 may receive a reference power flow signal (P ES1, REF ). This signal may be determined by the main power management controller located in the MCD 112 based on the motor power or grid power requirements and the state of the energy source 1 202 of the ConSource V2 module 108B. The power flow controller 1 1110 may estimate the maximum allowable charging and / or discharging current of the energy source 1 202 and calculate the actual permissible power flow (P ES1 ). This value can be compared with P CONSOURCE is compared, and the difference can be used as a signal (P ES2, REF ) is applied to the power flow controller 2 1120. The power flow controller 2 1120 can calculate the coupled inductor L based on the voltage between the output terminals out1 and out2 of the energy source 2 304. C The reference current in , and the switching signals of switches S1 and S2 of converter V2 308 are determined using, for example but not limited to, pulse width modulation or a hysteresis control algorithm. Therefore, the total power flow (P CONSOURCE ) can be provided by the switching part of the converter V2, which includes switches S3, S4, S5, S6. The power flow (P ES1 ) can be estimated based on the maximum permissible current of the energy source 1 and the actual conditions of the energy source 1, such as but not limited to the state of charge (SOC), the state of health (SOH), the temperature of the basic battery cell or the battery cell groups connected in parallel and / or in series, the equivalent series resistance, etc. The power flow (P ES1 ) can be maintained as load (P LOAD ) and Energy Source 2 (P ES2 ) is the difference between the current values, where P ES2 Managed by the switching section of converter V2 308, which includes switches S1, S2 and coupled inductor LC.

[0116] In many embodiments, energy source 2 304 may be a secondary energy source and its function is to assist energy source 1 202 by providing power at load power peaks and / or absorbing excess power. The secondary function of energy source 2 304 may be active filtering, such as reducing (attenuating) or eliminating any second-order current harmonics present in the current IDC_CONV flowing at the inputs in1 and in3 of converter V2 due to, for example, the inherent pulsating power nature of a single-phase system. Such harmonics may have considerable peak-to-peak values, which may be as high as twice the load current amplitude. Second-order current components exhibit some disadvantages, such as an increase in internal losses in energy source 1 202 associated with the resulting current RMS value. To perform this secondary function, energy source 2 304 may include an electrolytic capacitor or a supercapacitor (or ultracapacitor) as a separate component, or as Fig. 8A , 8B and connected in parallel with other energy storage elements as shown in 8D-8F.

[0117] Fig. 12A and 12B Examples of waveforms 1200, 1220 that occur before and during the execution of the active filtering secondary function are shown. Before compensation begins (before time t1), energy source 1 202 ( Fig. 12A ) includes a DC component (IDC=130A) and a second-order harmonic component with an amplitude of I2AC=60A. The high-frequency harmonics (not shown) determined by the switching behavior of converter V2 308 are efficiently buffered by energy buffer 204. Starting from time t1, converter V2 starts to generate current I ES2 , the current I ES1 The second harmonic is redirected to energy source 2. The current I ES2 With I ES1 The second harmonic of the current is equal to the main harmonic amplitude, but has an almost opposite phase angle, in such a way that the energy source 1 I ES1 The resulting current in includes only a DC component or a predominantly a DC component with some significantly reduced AC ripple, such as Fig. 12A In the case where only the converter V2 performs the secondary function, and if the energy source 2 only comprises capacitors and / or supercapacitors 810, the current I ES2 ( Fig. 12B ) may include a DC component that needs to be supplied from the load or from energy source 1 202 to maintain the voltage across the capacitor and / or ultracapacitor 810 of energy source 2 304 at a set value, which is required for proper operation of converter V2 308.

[0118] Both the primary and secondary functions performed by converter V2 and described above may be performed separately or simultaneously. If simultaneously, energy source 2 304 preferably comprises an electrolytic capacitor or supercapacitor 810 (such as Fig. 8A , 8B and 8D-8F).

[0119] Figure 3 1 is a diagram showing an LCD 114 for a ConSource V2 module, which is connected to the ConSource V2 module 108B via a set of diagnostic, measurement, protection and control signal lines, and can perform at least one, and preferably all, of four main functions. The first function is the management of Energy Source 1 202. The second function is the management of Energy Source 2 304. The third function is the protection of the Energy Buffer 204, and more specifically, the protection of its components from overcurrent, overvoltage and high temperature. The fourth function is the control and protection of the Converter V2 308.

[0120] The management functions of the energy source 1 for the ConSource V2 module 108B can be as follows. The LCD 114 receives measurement signals VES1, TES1, IES1, which are: VES1 - the voltage of all basic components / battery cells or the voltage of basic components / battery cell groups of the energy source 1, such as, for example but not limited to, individual or serially and / or parallel connected battery cells, individual or serially and / or parallel connected supercapacitor battery cells; TES1 - the temperature of all basic components of the energy source 1 or the temperature of the basic component group; IES1 - the output current of the energy source 1. Based on these measurement signals, the LCD can perform the following: calculate the real capacity, actual state of charge (SOC) and health state (SOH) of the basic component or the basic component group; set warning or alarm signals based on the measured and calculated data; transmit corresponding signals to the MCD 112.

[0121] The management functions of the Energy Source 2 304 for the ConSource V2 module 108B may be as follows. The LCD 114 may receive measurement signals VES2, TES2, IES2, which are: VES2—voltages of all elementary components or cells of the Energy Source 2 or voltages of groups of elementary components or cells, such as, for example but not limited to, individual or serially and / or parallel connected battery cells, individual or serially and / or parallel connected supercapacitor cells; TES2—temperatures of all elementary components of the Energy Source 2 or temperatures of groups of elementary components; IES2—output current of the Energy Source 2. Based on these measurement signals, the LCD may perform the following: calculate the real capacity, actual state of charge (SOC) and state of health (SOH) of an elementary component or group of elementary components; set warning or alarm signals based on the measured and calculated data; and / or transmit corresponding signals to the MCD.

[0122] The protection function of the energy buffer 204 for the ConSource V2 module 108B may be as follows. The LCD 114 receives the measurement signals VEB, TEB, IEB, which are: VEB - the voltage of at least one main component of the energy buffer, such as and not limited to capacitor CEB or capacitors CEB1, CEB2 (see Figures 7A-7C ); TEB - temperature of at least one main component of the energy buffer; and / or IEB - current through at least one main component of the energy buffer. Based on these measurement signals, the LCD can perform the following: set a fault (e.g., warning or alarm) signal based on the measurement data; and / or transmit a corresponding fault signal to the MCD 112.

[0123] The control and protection functions for the converter V2 308 of the ConSource V2 module 108B may be as follows. The LCD 114 receives a command signal from the MCD 112, which may be a modulation reference signal and an enable signal, or a reference signal and a modulation index, which may be used in a PWM and / or hysteresis function in the LCD to generate control signals for the semiconductor switches S1, S2, S3, S4, S5, S6 according to the power management and / or second-order harmonic reduction techniques described above. The integrated current sensor ( Figure 3 The current feedback signals IES2 and IOUT of the semiconductor device (not shown) can be connected to the drive circuit ( Figure 3The LCD 114 may be used for overcurrent protection together with a signal F (not shown) that carries information about the fault state (e.g., short circuit or open circuit fault mode) of one or more, preferably all semiconductor switches. Based on this specific data, the LCD 114 may make a decision about which combination of switch signals S1, S2, S3, S4, S5, S6 to apply to the corresponding semiconductor switch to bypass or disconnect the converter V2 and the entire ConSource V2 module from the system 100 (e.g., battery pack, etc.).

[0124] Figure 4 is a block diagram depicting an example embodiment of a ConSource module 108C, referred to as version 3 of the ConSource module (ConSource V3), and is an example of one type of converter-source module 108. ConSource V3 108C is communicatively coupled with LCD 114, which in turn is communicatively coupled with MCD 114.

[0125] The ConSource V3 module 108C may include an Energy Source Energy Source 1 202 and a Converter V2 308 having an additional input for connecting an Auxiliary Load 2 410, if desired. The ConSource V3 module has output ports 1 and 2 for connecting with other ConSource (e.g., V1 / V2 / V3) modules within the example system 100. The illustrated output ports 3 and 4 of the ConSource V3 are used to connect the example ConSource V3 module to the same output ports of other ConSource V3 modules of the example system 100, if desired, and / or to connect to Auxiliary Load 1 408, if desired. The illustrated output ports 5 and 6 of the ConSource V3 108C are used to connect the example ConSource V3 module to the same output ports of other ConSource V3 modules of the example system 100, if desired, and / or to connect to Auxiliary Load 2 410, if desired.

[0126] As with ConSource V1 108A, Energy Source 1 202 of ConSource V3 module 108C may be or include Figures 6A-6C Any examples described or otherwise.

[0127] The outputs out1 and out2 of Energy Source 1 202 are connected to input terminals in1 and in2 of Energy Buffer 204. As with ConSource V1 108A, Energy Buffer 204 of ConSource V3 module 108C may be or include a Figures 7A-7CAny examples described or otherwise.

[0128] The outputs out1 and out2 of the energy buffer 204 are connected to the inputs in1 and in3 of the converter V2 308, respectively. The converter V2 308 may be as described with respect to the ConSource V2 module 108B (e.g., with respect to Figure 5B ) is configured as discussed above. In this embodiment, the coupled inductor L C The output of is connected to port 5 of ConSource V3 module 108C and optional auxiliary load 2 410 via input In2 of converter V2 308, such as Figure 4 As shown in FIG. Assuming that the auxiliary load 2 has an input capacitor, the converter V2 308 can adjust, step down and stabilize the constant voltage required on the load, thereby adjusting the coupled inductor L C The voltage on the coupled inductor L C If no input capacitor is present, an optional capacitor (not shown) may be placed between In2 and In3 (or nodes 1 and in3) to form a coupled inductor L C For example, if Energy Source 1 is a battery module with a standard operating voltage of 48V (e.g., twelve 4V battery cells in series), and Auxiliary Load 2 requires 24V, S1 and S2 can be controlled to operate at a 50% duty cycle (where S1 is closed and S2 is open, then where S1 is open and S2 is closed), and based on feedback from current and / or voltage sensors, adjusted accordingly to maintain the voltage at a lower stepped-down level of 24V. Auxiliary Load 1 is coupled in parallel with Energy Source 1, and therefore operates at the same voltage as Energy Source 1 without regulation by Converter V2 308.

[0129] Additional auxiliary loads (e.g., auxiliary load 1) can be supplied by coupling outputs 3 and 4 to other loads operating at the same voltage as energy source 1, or alternatively by providing additional instances of outputs 3 and 4 for those additional loads. This can be accomplished by adding switch circuit 208 and coupled inductor L C The modules 108 described herein may be configured to supply any number of one or more auxiliary loads operating at the same or lower voltage level than the energy source 1.

[0130] The control switching signals of the semiconductor switches S3 , S4 , S5 , S6 may be generated in different ways depending on the flexibility and requirements of the control technology employed in the LCD 114 and the MCD 112 .

[0131] Energy source 1 202 may supply a corresponding portion of the power required by the load of system 100 , auxiliary load 1 408 , and / or auxiliary load 2 410 (if connected). Fig.13 An example of power flow management of the ConSource V3 module is shown, where the power flow between energy source 1, auxiliary load 1 and auxiliary load 2 can be adjusted. Examples of auxiliary loads can be, for example, an onboard electrical network of an electric vehicle, an HVAC system of an electric vehicle. The load of the system 100 can be, for example, an electric vehicle motor or one of the phases of the power grid. This embodiment can allow complete decoupling between the electrical characteristics of the energy source (terminal voltage and current) and the electrical characteristics of the load.

[0132] In these embodiments, reference is made to Fig.13 , power flow controller 1 1310 (PFC 1), power flow controller 2 1320 (PFC 2), power flow estimator 1 (PFE 1), and power flow estimator 2 (PFE 2) may be discrete control devices, separate from LCD 114 and MCD 112, and may be implemented as software within the LCD, may be implemented as hardware within the LCD, or may be implemented as a combination of hardware and software within the LCD. In some embodiments, the functionality of PFC 1, PFC 2, PFE 1, and PFE 2 may be shared or distributed between the LCD and the MCD. For ease of explanation, in the following embodiments, PFC 1, PFC 2, PFE 1, and PFE 2 are implemented as software instructions executed by the LCD.

[0133] PFE 1 may receive a reference power flow signal P for Energy Source 1 202 from a master power management controller (not shown) located in MCD 112 based on the load power requirements and the state of Energy Source 1 for that particular ConSource V3 module 108C. ES1, REF PFE1 can also receive signal P LOAD1 , the signal P LOAD1 is determined by the power consumption and / or generation of the auxiliary load 1 408 and in the power calculation block ( Fig.13 Energy Source 1 202 P TOT_REF_ES1 The total reference power flow can be P ES1, REF and P LOAD1 The PFC 1 1310 can estimate the maximum allowable charging and / or discharging current of the energy source 1 and calculate the actual allowable power flow P of the energy source 1. TOT,ES1 .

[0134] PFE 2 1320 may receive a total power flow signal P of energy source 1 from PFC 1 TOT,ES1 PFE2 can also receive signal P LOAD2 , the signal P LOAD2 is determined by the power consumption and / or generation of the auxiliary load 2 and in the power calculation block ( Fig.13 ), which is based on the current in auxiliary load 2 (e.g., measured by a current sensor that can be integrated in the ConSource V3 module, or received directly from auxiliary load 2 by the LCD). CONSOURCE The total reference power flow of the ConSourceV3 module can be P LOAD2 and P TOT,ES1 The total P CONSOURCE The power flow is provided by the switching part of each converter V2, each converter V2 includes switches S3, S4, S5, S6. LOAD2 can be managed by the switching part of the converter V2, which includes switches S1, S2 and coupled inductor L C .

[0135] Figure 4 1 and 2. An LCD 114 for a ConSource V3 module 180C is shown in FIG. It may be connected to the ConSource V2 module 108B via a set of diagnostic, measurement, protection and control signal lines and may perform at least one, and preferably all, of four main functions. A first function may be the management of the Energy Source 1 202. A second function may be the management of the Auxiliary Load 2 410. A third function may be the protection of the Energy Buffer 204, and more specifically, the protection of its components from overcurrent, overvoltage and high temperature. A fourth function may be the control and protection of the Converter V1.

[0136] In some example embodiments, the energy management function for the Energy Source 1 202 of the ConSource V3 module 108C may be as follows. The LCD 114 receives measurement signals VES1, TES1, IES1, which are: VES1 - voltages of all basic components / battery cells or voltages of groups of basic components / battery cells of the Energy Source 1 202, such as, for example but not limited to, individual or serially and / or parallel connected battery cells, individual or serially and / or parallel connected supercapacitor battery cells; TES1 - temperatures of all basic components or groups of basic components of the Energy Source 1; IES1 - output current of the Energy Source 1. Based on these measurement signals, the LCD may perform the following: calculate the real capacity, actual state of charge (SOC) and state of health (SOH) of the basic components or groups of basic components; set warning or alarm signals based on the measured and calculated data; transmit corresponding signals to the MCD.

[0137] The management functions of the auxiliary load 2 410 of the ConSource V3 module 108C can be as follows. The LCD receives the measurement signals VAL2, IAL2, which are: VAL2 - the voltage between the ports 5 and 6 of the ConSource V3 module; and IAL2 - the current in the coupled inductor LC of the converter V2, which is the current of the auxiliary load 2. In some embodiments, the LCD reports these signals (or their representation) to the MCD, which performs corrections by adjusting the modulation index of the module 108C. In other embodiments, based on these signals, the LCD performs corrections on the reference signal of the pulse width modulation in the LCD to stabilize and / or control the voltage on the auxiliary load 2.

[0138] The protection function of the energy buffer 204 of the ConSource V3 module 108C may be as follows. The LCD may receive measurement signals VEB, TEB, IEB, which are: VEB - the voltage of at least one main component of the energy buffer, such as and not limited to capacitor CEB or capacitors CEB1, CEB2 (see Figures 7A-7C ); TEB - temperature of at least one main component of the energy buffer 204; IEB - current through at least one main component of the energy buffer 204. Based on these measurement signals, the LCD can perform the following: set a fault (e.g., warning or alarm) signal based on the measurement data; and / or transmit a corresponding fault signal to the MCD.

[0139] The control and protection functions of the converter V2 308 of the ConSource V3 module 108C may be as follows. The LCD 114 receives a command signal from the MCD 112, which may be a modulation reference signal and an enable signal, or a reference signal and a modulation index, which may be used in a PWM and / or hysteresis function in the LCD to generate control signals for the semiconductor switches S1, S2, S3, S4, S5, S6 according to the above-mentioned power management and / or second-order harmonic reduction techniques. The integrated current sensor ( Figure 4 The current feedback signals IES2 and IOUT of the semiconductor device of the converter V2 can be connected to the drive circuit ( Figure 4The LCD may be used for overcurrent protection together with one or more signals F (not shown) that carry information about the fault state (e.g., short circuit or open circuit fault mode) of one or more, preferably all semiconductor switches. Based on this specific data, the LCD may make a decision about which combination of switch signals S1, S2, S3, S4, S5, S6 to apply to the corresponding semiconductor switch to bypass or disconnect the converter V2 308 and the entire ConSource V3 module from the system 100 (e.g., battery pack, etc.).

[0140] An example of a ConSource module is a converter-battery module having a battery as a first energy source. The converter-battery module may be referred to as a ConBatt module. The ConBatt module may be used, for example, in a battery pack for mobile applications such as an electric vehicle (EV). A system 100 configured to function as a battery pack having a plurality of ConBatt modules may be referred to as a ConBatt pack.

[0141] In other example embodiments, the ConSource module may be connected to an additional power source such as a photovoltaic panel and / or a wireless charging receiver. In other example embodiments, the system 100 may be connected to another system 100 (e.g., another ConBatt pack) coupled to other auxiliary loads of different voltage levels, such as, for example, an EV's onboard electrical network system and air conditioning.

[0142] Features of one example embodiment of a ConSource module V1, V2, or V3 may be combined with features of another example embodiment of a ConSource module V1, V2, or V3 as desired. For example, ConSource modules V1 and V2 may each be configured to supply auxiliary loads 1 and / or 2, as described with respect to ConSource module V3. As another example, ConSource modules V1 and V3 may each be configured with a second energy source (Energy Source 2), as described with respect to ConSource module V2.

[0143] Example embodiments of module arrangements for module-based systems

[0144] Figure 15-29 Depicted are example embodiments of the system 100 arranged according to various architectures or configurations. In these embodiments, the system 100 can be configured into one or more modules packages, although the embodiments are not limited to packages. For ease of illustration, the MCD and LCD in each embodiment are not shown. As can be seen, the modules can be arranged in many ways so that the power contributed by each module can be summed to form, for example, one or more of a single-phase AC output, a multi-phase AC output, and a DC output.

[0145] Fig.15 An example embodiment of a ConSource package 1500 including a one-dimensional array of N number of connected ConSource modules 108-1, 108-2, ... 108-N according to the present disclosure is shown. The one-dimensional array may also be referred to as an N-stage cascade, where each stage corresponds to a module 108. If desired, all modules 108 shown here may be combined in a single energy package, where the modules 108 are co-located in a single common housing or enclosure. Each ConSource module in the array may be configured as described above with reference to Figure 2 , 3 and 4. The plurality of ConSource modules may include modules configured according to the same module version (V1, V2, or V3), or a mixture of modules configured according to two or more of the three module versions (V1, V2, and V3). A first port 1 of a ConSource V1 / V2 / V3 module in a first row of the one-dimensional array ("first ConSource V1 / V2 / V3 module") is connected to a first output terminal out1 of the one-dimensional array of ConSource modules. A second port 2 of the first ConSource V1 / V2 / V3 module is connected to a first port 1 of a ConSource V1 / V2 / V3 module in a second row ("second ConSource V1 / V2 / V3 module"). The second port 2 of the second ConSource V1 / V2 / V3 module is connected to the first port of the ConSource V1 / V2 / V3 module in the third row ("third ConSource V1 / V2 / V3 module"), and so on further down to the Nth ConSource V1 / V2 / V3 module in the Nth or last row in the same order. The second port 2 of the Nth ConSource V1 / V2 / V3 module is connected to the second output terminal out 2 of the one-dimensional array 1500. The one-dimensional array of this number N connected ConSource modules can be used as a DC or single-phase AC energy source, such as, for example, a battery pack, for stationary energy storage applications of a DC or AC single-phase load. The DC or AC single-phase load can be connected between the first and second output terminals out1 and out2.

[0146] The output voltage of the one-dimensional array of number N connected ConSource modules can be generated using, for example, but not limited to, space vector modulation or sinusoidal pulse width modulation ("PWM") using phase shift carrier techniques. The switching signals for the converter of each ConSource module can then be generated using phase shift carrier techniques. This technique ensures that the ConSource modules rotate continuously and that power is distributed nearly equally among them.

[0147] The example purpose of the phase shifting technique is to generate a multi-level output PWM waveform using an incrementally offset two-level waveform. Thus, an X-level PWM waveform is created by summing (X-1) / 2 two-level PWM waveforms. These two-level waveforms are created by summing a reference waveform Vref with a triangular carrier wave 1400, 1410 (1400, 1410) incrementally offset by 360º / (X-1). Fig.14A , 14B ) is generated by comparison. Fig.14A A 9-level example 1400 (using four modules 108) is shown in FIG. 1 . The carrier increment is offset by 360º / (9-1) = 45º and compared to the reference waveform. The resulting two-level PWM waveform 1420 is Fig. 14C . These two-level waveforms can be used as switching signals for the semiconductor switches of the converters in each ConSource module 108. As an example, for a one-dimensional array comprising four cascaded ConSource modules, each ConSource module having a converter V1 (where S3, S4, S5, S6 are arranged in an H-bridge), the 0° signal is used for S3, and the 180° signal is used for S6 of the first ConSource module, the 45° signal is used for S3, and the 225° signal is used for S6 of the second ConSource module, and so on. Note that in all converters V1 / V2 / V3, the signal of S3 is complementary to S4, and the signal of S5 is complementary to S6, together with a certain dead time to avoid breakdown of each branch. Fig.14D An example AC waveform resulting from the superposition of output voltages from four modules is depicted.

[0148] Depending on the resources and limitations of the hardware used to implement the modulation, one alternative is to generate a negative reference signal along with the initial (N-1) / 2 carriers. Fig. 14B A 9-level example is shown in . In this case, the 0° to 135° PWM signal is generated by comparing Vref to the corresponding carrier, and the 180° to 315° PWM signal is generated by comparing -Vref to the 0° to 135° carrier. However, the comparison logic in the latter case must be reversed. Other techniques such as a state machine decoder can also be used to generate the gate signals for the H-bridge.

[0149] In multi-phase system embodiments, the same carrier may be used for each phase, or the carrier group may be offset as a whole for each phase. For example, in a three-phase system, each phase array may use the same number of carriers with the same relative offset (e.g. Fig.14A and 14B), but the carrier of the second phase is offset by 120 degrees compared to the carrier of the first phase, and the carrier of the third phase is offset by 240 degrees compared to the carrier of the first phase. In many cases, the carrier frequency will be fixed, but in some example embodiments, the carrier frequency can be adjusted. Adjustment of the carrier frequency can help reduce losses in the EV motor under high current conditions.

[0150] Fig.15 This one-dimensional array 1500 embodiment of the system 100 shown in enables: using low voltage and / or medium voltage rated energy source elements and switching components (MOSFET, JFET, IGBT, etc.) in the ConSource module with significantly reduced switching and conduction losses, to obtain a high voltage of any shape with very low total harmonic distortion between the first and second terminals out1 and out2.

[0151] Fig.16 An example embodiment of a first version of a ConSource package according to the present disclosure comprising a two-dimensional array 1600 or two one-dimensional arrays 1500 of N number of connected ConSource V1 / V2 / V3 modules 108-1, 108-2, ... 108-N. The output of the DC or AC voltage generated by each of the two one-dimensional arrays 1500 forming the two-dimensional array 1600 is described above with reference to Fig.15 If desired, all modules 108 shown here can be combined in a single energy package, where the modules 108 are co-located in a single common housing or enclosure. The second port 2 of each of the NConSource V1 / V2 / V3 modules in the Nth or last row of the two one-dimensional arrays is connected together and connected to the common output terminal Out3 of the two-dimensional array. An output voltage is provided between the first and second output terminals Out1 and Out2 and the common output terminal Out3.

[0152] This two-dimensional array of 2N connected ConSource V1 / V2 / V3 modules can be used as a two-phase AC energy source for stationary energy storage applications for DC or AC single-phase loads. If desired, a load can be connected between the first and second output terminals Out1 and Out2, while the common terminal Out3 can be connected to the neutral point of the load.

[0153] When the common output terminal out3 is connected to the second terminal of the AC or DC load, the first and second output terminals out1 and out2 of the example two-dimensional array-based ConSource pack can be connected together via a coupled inductor and connected to the same first terminal of the AC or DC load. In this case, the output power capability of such a two-dimensional array-based ConSource pack with N rows is twice as high as the output power capability of a one-dimensional array-based ConSource pack with the same number of N rows.

[0154] Fig.16 This two-dimensional array embodiment of the system 100 shown in enables a two-phase system with a high voltage having a 90 degree phase shift to be obtained. For example, such a system can be used in an electric furnace. In general, using low voltage and / or medium voltage rated energy source elements and switch components (MOSFET, JFET, IGBT, etc.) with significantly reduced switching and conduction losses in the ConSource module, a high voltage of any shape with very low total harmonic distortion can be obtained between the terminals out1, out2 and the common terminal out3 (which can be used as a neutral point).

[0155] Fig.17 An example embodiment of a second version of a ConSource package including a two-dimensional array 1700 or two one-dimensional arrays of N and N+1 connected ConSource modules 108-1, 108-2, ... 108-N according to the present disclosure is shown. Fig.15 The output of the DC or AC voltage generation of each of two one-dimensional arrays 1500 having N and N+1 interconnected ConSource modules forming the two-dimensional arrays is depicted. If desired, all modules 108 shown here can be combined in a single energy package, wherein the modules 108 are co-located in a single common housing or enclosure. The second port 2 of each of the Nth ConSource V1 / V2 / V3 modules in the Nth or last row of the two one-dimensional arrays is connected to the first and second ports 1 and 2 of the additional or N+1th ConSource V1 / V2 / V3 module.

[0156] This two-dimensional array of 2N+1 connected ConSource V1 / V2 / V3 modules can be used as a single-phase AC energy source for stationary energy storage applications for DC or AC single-phase loads. The load can be connected between the first and second output terminals Out1 and Out2 of the first ConSource V1 / V2 / V3 module in the first row of each one-dimensional array.

[0157] Fig.18An example embodiment of a first version of a ConSource package according to the present disclosure is shown, comprising a plurality of ConSource V1 / V2 / V3 modules 108-1, 108-2, ... 108-N connected in a three-dimensional array 1800. If desired, all modules 108 shown here may be combined in a single energy package, wherein the modules 108 are co-located in a single common housing or enclosure. The first, second and third output terminals out1, out2 and out3 of the ConSource package are connected to the first port 1 of the first ConSource V1 / V2 / V3 module of the first row of each of the three one-dimensional arrays 1500, which form the ConSource package based on the three-dimensional array 1800. The above referenced Fig.15 The output of the DC or AC voltage generation of each of the three one-dimensional arrays 1500 forming the ConSource package based on the three-dimensional array 1800 is described. The second port 2 of the Nth ConSource V1 / V2 / V3 module in the Nth row or the last row of each of the three one-dimensional arrays is connected together and connected to the common output terminal out4 of the three-dimensional array. The output voltage is provided between the first, second and third output terminals out1, out2, out3 and the common output terminal out4.

[0158] This three-dimensional array 1800 of 3N connected ConSource V1 / V2 / V3 modules 108-1, 108-2...108-N can be used as a three-phase AC energy source for stationary energy storage or electric vehicle applications for DC or AC single loads, three-phase loads, three-phase grids or three-phase motors 2200, such as Fig. 22 As shown in . If necessary, a three-phase load can be connected between the first, second and third output terminals out1, out2, out3, and the common output terminal out4 can be connected to the neutral point of the load.

[0159] When the common output terminal out4 is connected to the second terminal of a DC or single-phase AC load, the first, second and third output terminals out1, out2 and out3 of the three-dimensional array-based ConSource pack can be connected together via coupled inductors and connected to the same first terminal of the DC or single-phase AC load. In this case, the output power capability of such a three-dimensional array-based ConSource pack with N rows is three times higher than that of an ACi battery pack based on a single-dimensional array with the same number of N rows.

[0160] Fig.19This three-dimensional array 1900 embodiment of the system 100 shown in enables: using low and / or medium voltage rated energy source elements and switching components (MOSFET, JFET, IGBT, etc.) in the ConSource module with significantly reduced switching and conduction losses, to obtain a high voltage three-phase system of any shape with very low total harmonic distortion between terminals ou1, out2, out3 and a common terminal out3 (which can be used as a neutral point). Such a system can be connected to a power distribution network and can be used as an active power source or buffer, a reactive power compensator and a power factor corrector, an active harmonic filter with very high dynamic response, and a passive filter of significantly reduced size between out1, out2, out3 and the grid phase. The system can also be connected to a three-phase load that is provided with energy from an energy source element such as a battery, an ultracapacitor, a fuel cell unit, etc.

[0161] Fig.19 An example embodiment of a second version of a ConSource pack according to the present disclosure is shown including a plurality of ConSource modules 108-1, 108-2, ... 108-N connected in a three-dimensional array 1900. If desired, all of the modules 108 shown here may be combined in a single energy pack, wherein the modules 108 are co-located in a single common housing or enclosure.

[0162] The first port 1 of the ConSource V1 / V2 / V3 module 108-1 ("first ConSource V1 / V2 / V3 module") of the first row of each of the three one-dimensional arrays 1500 is connected to the first, second and third output terminals out1, out2 and out3 of each of the three one-dimensional arrays, which form the three-dimensional array-based ConSource package. Fig.15 Output DC or AC voltage generation is depicted for each of three one-dimensional arrays having a number N of connected ConSource V1 / V2 / V3 modules forming the three-dimensional arrays. The second port 2 of a first ConSource V1 / V2 / V3 module 108-1 is connected to a first port 1 of a ConSource V1 / V2 / V3 module 108-2 ("second ConSource V1 / V2 / V3 module") in a second row of the three one-dimensional arrays. The second port 2 of the second ConSource V1 / V2 / V3 module is connected to a first port 1 of a ConSource V1 / V2 / V3 module in a third row of the three one-dimensional arrays (not shown), and so on further down in the same order to a number M rows of ConSource V1 / V2 / V3 modules, where M is 2 or greater.

[0163] The first port 1 of the ConSource V1 / V2 / V3 module in the M+1th row is connected to the second port 2 (not shown) of the ConSource V1 / V2 / V3 module in the Mth row. The second port 2 of the ConSource V1 / V2 / V3 module in the M+1th row is connected to the first port 1 (not shown) of the ConSource V1 / V2 / V3 module in the M+2th row. The second output port 2 of the ConSource V1 / V2 / V3 module in the M+2th row is connected to the first port 1 (not shown) of the ConSource V1 / V2 / V3 module in the M+3th row, and so on further down to the ConSource V1 / V2 / V3 modules in the M+Nth row in the same order.

[0164] The second port 2 of the ConSource V1 / V2 / V3 module in the last row or the M+N row of the first column 1500 of the three-dimensional array is connected to the first port 1 of the ConSource V1 / V2 / V3 module in the M+1 row of the second column 1500' of the three-dimensional array. The second port 2 of the ConSource V1 / V2 / V3 module in the last row or the M+N row of the second column of the three-dimensional array is connected to the first port 1 of the ConSource V1 / V2 / V3 module in the M+1 row of the third column 1500'' of the three-dimensional array. The second port 2 of the ConSource V1 / V2 / V3 module in the last row or the M+N row of the third column of the three-dimensional array is connected to the first port 1 of the ConSource V1 / V2 / V3 module in the M+1 row of the first column of the three-dimensional array.

[0165] This three-dimensional array of connected ConSource V1 / V2 / V3 modules can be used as a three-phase energy source for stationary energy storage or electric vehicle applications for DC or AC single loads, three-phase loads, three-phase grids or three-phase motors, such as Fig.23 as shown in .

[0166] In addition to about Fig.18 In addition to the advantages mentioned, Fig.19 This three-phase (three-dimensional array) configuration embodiment of the system 100 shown in FIG. 1 - with a combination of series-connected and delta-connected ConSource modules - enables efficient energy exchange (phase balancing) between all ConSource modules of the system and the phases of the grid or load. The combination of delta- and series-connected ConSource modules allows the total number of ConSource modules in the array to be reduced to obtain a desired output voltage.

[0167] Fig. 20An example embodiment of a third version of a ConSource package according to the present disclosure is shown that includes a plurality of ConSource modules connected in a three-dimensional array 2000. If desired, all modules 108 shown here can be combined in a single energy package, wherein the modules 108 are co-located in a single common housing or enclosure. The first, second and third output terminals out1, out2 and out3 of the ConSource package are connected to the first port 1 of the ConSource V1 / V2 / V3 module 108-1 of the first row of three one-dimensional arrays 1500 that form the ConSource package based on the three-dimensional array 2000. The above referenced Fig.15 Output DC or AC voltage generation is described for each of three one-dimensional arrays having a number N of connected ConSource V1 / V2 / V3 modules 108-1, 108-2, ... 108-N forming the three-dimensional array. The second port 2 of the ConSource V1 / V2 / V3 module of the Nth row of the first column of the three-dimensional array is connected to the first port 1 of the first additional ConSource V3 module, which serves as the interconnect (IC) module 108-IC of the N+1th row. The second port 2 of the ConSource V1 / V2 / V3 module of the Nth row of the second column of the three-dimensional array is connected to the second port 2 of the first additional ConSource V3 module 108-IC of the N+1th row. The second port 2 of the ConSource V1 / V2 / V3 module of the Nth row of the third column of the three-dimensional array is connected to the first port 1 of the second additional ConSource V3 module 108-IC of the N+1th row. The second port 2 of the second additional ConSource V3 module is connected to the fourth output terminal Out4 of the ConSource package. The third and fourth ports 3 and 4 of the first and second additional ConSource V3 modules of row N+1 are interconnected, such as Fig. 20 as shown in .

[0168] This three-dimensional array of connected ConSource V1 / V2 / V3 modules can be used as a three-phase energy source for stationary energy storage or electric vehicle applications for DC or AC single loads, three-phase loads, three-phase grids or three-phase motors, such as Fig.24 A three-phase load may be connected between the first, second and third output terminals out1, out2 and out3, and the fourth output terminal out4 may be used as a charging terminal.

[0169] In addition to about Fig.18 In addition to the advantages mentioned, Fig. 20This three-phase (three-dimensional array) configuration embodiment of the system 100 shown in FIG. 1—with two additional interconnected ConSource V3 modules 108 -IC—enables efficient and rapid energy exchange (phase balancing) between all ConSource modules of the system and the phases of the grid or load.

[0170] Fig.21 An example embodiment of a fourth version of a ConSource package according to the present disclosure is shown that includes multiple ConSource modules connected in a multi-dimensional array 2100 (including K one-dimensional arrays 1500), where K is 3 or greater as an example, and is shown in an example orientation diagram with multiple rows and K columns for presentation and reference purposes only. If desired, all of the modules 108 shown here can be combined in a single energy package, where the modules 108 are co-located in a single common housing or enclosure. Each of the K one-dimensional arrays 1500 includes M+N ConSource V1 / V2 / V3 modules 108-1...108-(M+N) having first and second ports. Each of the first, Kth, and other odd integer one-dimensional arrays includes an M+N+1th additional ConSource V3 module 108-IC having first, second, third, and fourth ports.

[0171] The first port 1 of the ConSource V1 / V2 / V3 module of the first row of each of the K number of one-dimensional arrays is connected to the individual output terminals of the first and second output terminals out1 and out2, respectively, and so on to the K-th output terminal outK of the K number of one-dimensional arrays forming the multi-dimensional array-based ConSource package. The second port 2 of the ConSourceV1 / V2 / V3 module in the first row is connected to the first port 1 (not shown) of the ConSourceV1 / V2 / V3 module in the second row of each of the K number of one-dimensional arrays. The second port 2 of the ConSource V1 / V2 / V3 module in the second row is connected to the first port 1 (not shown) of the ConSource V1 / V2 / V3 module in the third row of each of the K number of one-dimensional arrays, and so on further down to the ConSource V1 / V2 / V3 modules of the M number of rows in the same order, where M is 2 or greater.

[0172] The second port 2 of the ConSource V1 / V2 / V3 module 108-M of the first array column of the Mth row is connected to the first port 1 of the ConSource V1 / V2 / V3 module 108-1 of the second array column of the first row. The second port 2 of the ConSource V1 / V2 / V3 module 108-M of the second array column of the Mth row is connected to the first port 1 of the ConSource V1 / V2 / V3 module 108-1 of the third array column of the first row, and so on in the same order up to the Kth array column, where the second port 2 of the ConSource V1 / V2 / V3 module 108-M in the Kth array column of the Mth row is connected to the first port 1 of the ConSource V1 / V2 / V3 module 108 of the first array column of the first row.

[0173] The first port 1 of all the first to Kth array columns of the ConSource V1 / V2 / V3 modules 108-(M+1) of the M+1th row is connected to the second port 2 of the ConSource V1 / V2 / V3 module 108-M of the Mth row. The second port 2 of all the first to Kth array columns of the ConSource V1 / V2 / V3 modules 108-(M+1) of the M+1th row is connected to the first port 1 of all the first to Kth columns of the ConSource V1 / V2 / V3 modules of the M+2th row, and so on further down to the number N rows of ConSource V1 / V2 / V3 modules in the same order, where N is 2 or greater.

[0174] The second port 2 of the ConSource V1 / V2 / V3 module of the M+Nth row of the first array column of the multidimensional array is connected to the first port 1 of the first additional ConSource V3 module of the M+N+1th row. The second port 2 of the ConSource V1 / V2 / V3 module of the M+Nth row of the second array column of the multidimensional array is connected to the second port 2 of the first additional ConSource V3 module of the M+N+1th row. The second port 2 of the ConSource V1 / V2 / V3 module of the M+Nth row of the K-2th array column of the multidimensional array is connected to the first port 1 of the ((K-1) / 2)th additional ConSource V3 module of the M+N+1th row. The second port 2 of the ConSource V1 / V2 / V3 module of the M+Nth row of the K-1th column of the multidimensional array is connected to the second port 2 of the ((K-1) / 2)th additional ConSource V3 module of the M+N+1th row. The second port 2 of the ConSource V1 / V2 / V3 module in the M+Nth row of the Kth column of the multidimensional array is connected to the first port 1 of the (K+1) / 2th additional ConSource V3 module in the M+N+1th row. The second port 2 of the (K+1) / 2th additional ConSource V3 module is connected to the Kth output terminal outK+1 of the ConSource package. Fig.21 As shown in , output ports 3 and 4 of all (K+1) / 2 additional ConSource V3 modules in row M+N+1 are connected together.

[0175] This multi-dimensional array of connected ConSource V1 / V2 / V3 modules can be used as a multi-phase energy source for stationary energy storage or electric vehicle applications for DC loads, multi-phase AC loads, multi-phase grids or multi-phase electric machines.

[0176] In addition to about Fig.18 In addition to the advantages mentioned, Fig.21 This multi-dimensional array 2100 embodiment of the system 100 shown in FIG. 1—having a combination of delta-connected and series-connected ConSource modules and additional interconnected ConSource V3 modules—enables efficient and rapid energy exchange (phase balancing) between all ConSource modules of the system and the phases of the grid or load. The combination of delta- and series-connected ConSource modules allows for a reduction in the total number of ConSource modules in the array to obtain a desired output voltage.

[0177] Fig. 22 and Fig.23 They are shown respectively as Fig.18 and Fig.19The example embodiments of the first and second versions of the ConSource packages 1800, 1900 presented in FIG. 1 and further connected to any type of three-phase motor 2200. If desired, Fig. 22 All modules 108 shown in can be combined in a single energy pack, where the modules 108 are co-located in a single common housing or enclosure. The same applies to Fig.23 All modules 108 shown in FIG.

[0178] Fig. 22 The three-dimensional array 1800 (three-phase motor drive system) embodiment of the system 100 shown in makes it possible to obtain a high voltage three-phase system of any shape with very low total harmonic distortion between motor phases A, B and C using low and / or medium voltage rated energy source elements and switching components (MOSFETs, JFETs, IGBTs, etc.) with significantly reduced switching and conduction losses. Such a system does not require bulky passive filters as in the case of a 2-level inverter and has a high dynamic response.

[0179] In addition to about Fig. 22 In addition to the advantages mentioned, Fig.23 The three-phase motor drive embodiment 1900 of the system 100 (three-dimensional array) shown in FIG. 1900 —with a combination of series-connected and delta-connected ConSource modules 108—enables efficient energy exchange (phase-to-phase balancing) between all ConSource modules of the system and all phases of the motor 2200. The combination of delta- and series-connected ConSource modules allows for a reduction in the total number of ConSource modules in the array to obtain a desired output motor voltage.

[0180] Fig.24 22 shows an example embodiment of a third version of a ConSource package connected to any type of three-phase motor 2200. If desired, all modules 108 shown here can be combined in a single energy package, where the modules 108 are co-located in a single common housing or enclosure. Fig.21 , where K is equal to 3, wherein the third and fourth output ports 3 and 4 of the two additional ConSource V3 modules 108-IC in the N+1th row are connected together and connected to the second auxiliary load 2. The two additional ConSource V3 modules in the N+1th row further include fifth and sixth output ports 5 and 6 connected together and connected to the first auxiliary load 1 408. The first auxiliary load 1 and the second auxiliary load 2 410 have different voltages and respectively represent, for example but not limited to, an on-board network system and an air conditioning power supply system of an electric vehicle.

[0181] In addition to about Fig.21 In addition to the advantages mentioned, Fig.24 This three-phase motor drive embodiment 2400 of the system 100 (three-dimensional array) shown in FIG. 2400 - with a combination of series-connected and delta-connected ConSource modules 108 and two additional interconnected ConSource V3 modules 108-IC - enables efficient and fast energy exchange (phase-to-phase balancing) between all ConSource modules of the system and the phases of the motor 2200. The combination of delta- and series-connected ConSource modules allows reducing the total number of ConSource modules in the array to obtain the desired output motor voltage. The additional output terminals 3, 4, 5, 6 of the interconnected ConSource V3 modules provide different levels of low voltage that can be used to provide power to auxiliary loads, which in turn represent, for example, the electric on-board network and HVAC power lines of an electric vehicle. In this case, no additional low-voltage battery is needed; the energy of the system mentioned above is delivered by the entire array of ConSource modules.

[0182] Fig.25 An example embodiment 2500 of a fourth version of a ConSource package connected to any type of three-phase motor 2200 is shown. If desired, all modules 108 shown here can be combined in a single energy package, where the modules 108 are co-located in a single common housing or enclosure. Fig. 20 , wherein the third and fourth output ports 3 and 4 of the two additional ConSource V3 modules 108 in the N+1th row are connected together and connected to the second auxiliary load 410. The two additional ConSource V3 modules in the N+1th row further include fifth and sixth output ports 5 and 6 connected together and connected to the first auxiliary load 408. The first auxiliary load 408 and the second auxiliary load 410 have different voltages and represent, for example but not limited to, an on-board network system and an air conditioning power supply system of an electric vehicle, respectively.

[0183] In addition to about Fig. 22 In addition to the advantages mentioned, Fig.25This three-phase motor drive embodiment of the system 100 (three-dimensional array) shown in FIG. 1 - with two additional interconnected ConSource V3 modules 108-IC - enables efficient and fast energy exchange (phase-to-phase balancing) between all ConSource modules and phase motors of the system. The additional output terminals 3, 4, 5, 6 of the interconnected ConSourceV3 modules 108-IC provide low voltages of different levels, which can be used to provide power to auxiliary loads, which in turn represent, for example, the electric on-board network and HVAC power lines of an electric vehicle. In this case, no additional low-voltage battery is needed; the energy of the system mentioned above is delivered by the entire ConSource module array.

[0184] Fig.26 An example embodiment 2600 of a fifth version of a ConSource package connected to any type of six-phase motor 2650 is shown. If desired, all modules 108 shown here can be combined in a single energy package, where the modules 108 are co-located in a single common housing or enclosure. Fig.25 , wherein the first and second array columns of the three-dimensional array 2500 are repeated twice to form a Fig.25 The three groups of first and second array columns of the six-dimensional array shown in FIG. The third and fourth ports 3 and 4 of the three additional ConSource V3 modules 108-ICs in the N+1th row are connected together and connected to the second auxiliary load 2 410, and the fifth and sixth ports 5 and 6 of the three additional ConSource V3 modules 108-ICs in the N+1th row are connected together and connected to the first auxiliary load 1 408. The first auxiliary load 408 and the second auxiliary load 410 have different voltages and respectively represent, for example but not limited to, an on-board network system and an air conditioning power supply system of an electric vehicle.

[0185] In addition to about Fig. 22 In addition to the advantages mentioned, Fig.26 This three-phase motor drive embodiment of the system 100 (three-dimensional array) shown in FIG. 1 - with three additional interconnected ConSource V3 modules 108-IC - enables efficient and fast energy exchange (phase-to-phase balancing) between all ConSource modules and all six-phase motors of the system. The additional output terminals 3, 4, 5, 6 of the interconnected ConSource V3 modules provide different levels of low voltage that can be used to provide power to auxiliary loads, which in turn represent, for example, the electric on-board network and HVAC power lines of an electric vehicle. In this case, no additional low-voltage battery is required; the energy of the above-mentioned system is delivered by the entire six-dimensional array of ConSource modules.

[0186] Fig.27A An example embodiment of a sixth version of the system 100 is shown, having two ConSource systems 2700 and 2700', each ConSource system including N rows of ConSource modules connected in a three-dimensional array. System 2700 is configured as the primary power supply for a three-phase motor 2200, while system 2700' is configured as the primary power supply for a three-phase motor 2200'. Both systems 2700 and 2700' may operate at different voltages and frequencies. System 2700 includes an N+1th row of IC modules 108-IC coupled to an auxiliary load and an Nth row of modules 108-N of system 2700'.

[0187] Each system 2700, 2700' can be independently configured into a single common electrical and mechanical unit or package, where the modules 108 are placed adjacent to or in close proximity to each other and share the same cooling system. Each of the packages 2700, 2700' can be located in its own separate and independent housing or enclosure 2705, 2705', respectively. In other embodiments, Fig.27A All modules 108 shown in may be combined into one common package. In yet another embodiment, any of the aforementioned configurations may be used, but with the IC modules 108-IC in one or more separate packages, separate from the package(s) holding the other cascaded modules 108.

[0188] The first, second and third terminals A, B and C of the first motor 1 2200 are connected to the ConSource package at the first port 1 of the ConSource V1 / V2 / V3 module 108-1 in the first row of the package 2700. The second port 2 of the ConSource V1 / V2 / V3 module in the Nth row of all three array columns of the package 2700 is connected to the first port 1 of the three corresponding IC modules 108-IC in the N+1th row, as shown in FIG. Fig.27A . The second port 2 of all three IC modules 108-IC in row N+1 is connected to the second port 2 of the ConSource V1 / V2 / V3 module 108-N in row N of package 2700'. The first, second and third output terminals A', B' and C' of motor 2200' are connected to the first port 1 of the ConSource V1 / V2 / V3 module in row 1 of ConSource package 2700'. The second port 2 of the ConSource V1 / V2 / V3 module 108-1 in row 1 is connected to the second port 2 of the ConSource V1 / V2 / V3 module 108-2 in row 2 of package 2700', and so on in the same order further down to the last row or row N of package 2700', as shown in FIG. Fig.27A as shown in .

[0189] The third and fourth ports 3 and 4 of the IC module 108-IC are connected together and connected to the first auxiliary load 408. The fifth and sixth ports 5 and 6 of the three IC modules 108-IC are connected together and connected to the second auxiliary load 410. The first auxiliary load and the second auxiliary load have different voltages and respectively represent, for example but not limited to, an on-board network system and an air conditioning power supply system of an electric vehicle.

[0190] Fig.27A This three-dimensional array embodiment of the system 100 shown in with three additional interconnected ConSource V3 modules 108-IC provides independent voltage and frequency regulation (control) for at least two independent motors (e.g., a dual motor drive system), and enables efficient and rapid energy exchange (phase balancing) between all ConSource modules and the phases of the two motors of such a dual motor system. The additional output terminals 3, 4, 5, 6 of the interconnected ConSource V3 modules provide different levels of low voltage, which can be used to provide power to auxiliary loads, which in turn represent, for example, the electric vehicle's electric onboard network and HVAC power lines. In this case, no additional low-voltage battery is required; the energy for the above-mentioned system is delivered by the entire ConSource module array. In this embodiment, the IC module 108-IC is shown as part of the package 2700, but in other embodiments, the IC module 108-IC can be outside the packages 2700 and 2700', either as an independent entity, or in a third package containing three IC modules 108-IC. Fig.27A The configuration can be used in a variety of stationary and mobile applications, including EVs with two in-wheel motors 2200 and 2200', which can be motors for the two front wheels (front wheel drive) or the two rear wheels (rear wheel drive). Regardless of whether auxiliary loads 408 and 410 are supplied, this embodiment permits inter-phase balancing (e.g., inter-system or inter-pack balancing) within each individual system and between phases across the two systems.

[0191] Fig.27B Another example embodiment of the system 100 is shown, wherein reference is made to Fig.27AThe described system has been replicated to implement four systems 2750, 2750', 2750", 2750'" as the primary supply for four motors 2200, 2200', 2200", 2200'", respectively. Each system 2750, 2750', 2750", 2750'" includes multiple rows of modules 108 connected in a three-dimensional array, where system 2750 has N rows, system 2750' has M rows, system 2750" has P rows, and system 2750'" has Q rows. Although the number of rows can be the same (N=M=P=Q) in many embodiments, the number of rows (and therefore the cascade stages) in each system can be different. All four systems can operate at different voltages and frequencies. System 2750 includes the N+1th row of modules 108-IC implemented as IC modules, which are coupled to auxiliary loads 1 and 2 and the Mth row of modules 108 of system 2750'. System 2750" includes a P+1th row of modules 108-IC implemented as IC modules, which are also coupled to auxiliary loads 1 and 2 and a Qth row of modules 108 of system 2750".

[0192] Each system 2750, 2750', 2750", 2750'" can be independently configured into a single common electrical and mechanical unit or package, where the modules 108 are placed adjacent to or in close proximity to each other and share the same cooling system. Each of the packages 2750, 2750', 2750", 2750'" can be located in its own separate and independent housing or enclosure 2705, 2705', 2705", 2705'", respectively. In other embodiments, Fig.27B All modules 108 shown in the can be combined into a common package, or two of the four systems can be implemented as a first package (e.g., dedicated to the front wheels of the EV), and the other two of the four systems can be implemented as a second package (e.g., dedicated to the rear wheels of the EV). In yet another embodiment, any of the aforementioned configurations can be used, but with the IC modules 108-IC in one or more separate packages, separate from the package(s) holding the other cascaded modules 108.

[0193] The first, second, and third terminals A1, B1, and C1 of the motor 2200 are connected to the system 2750 at the first port 1 of the ConSource V1 / V2 / V3 module 108-1 of the first row of the system 2750. The second port 2 of the ConSource V1 / V2 / V3 module of the first row may be coupled to any number of intermediate rows (not shown) in a cascaded manner as described herein, up to the first port of the Nth row of all three array columns of the system 2750. The second port of the Nth row of modules 108 is connected to the first port 1 of the three corresponding IC modules 108-IC of the N+1th row, as shown. Fig.27B. The second ports 2 of all three IC modules 108-IC in the N+1th row are connected to the second port 2 of the ConSource V1 / V2 / V3 module 108 in the Mth row of the system 2750'. The first, second, and third output terminals A2, B2, and C2 of the motor 2200' are connected to the first port 1 of the ConSource V1 / V2 / V3 module in the first row of the system 2750'. The second port 2 of the ConSource V1 / V2 / V3 module 108-1 in the first row is connected to any number of intermediate rows (not shown) in a cascaded manner as described herein, up to the first port of the Mth row of all three array columns of the system 2750.

[0194] The first, second, and third terminals A3, B3, and C3 of the motor 2200″ are connected to the system 2750″ at the first port 1 of the ConSource V1 / V2 / V3 module 108-1 of the first row of the system 2750″. The second port 2 of the ConSource V1 / V2 / V3 module of the first row may be coupled to any number of intermediate rows (not shown) in a cascaded manner as described herein, up to the first port of the Pth row of all three array columns of the system 2750″. The second port of the Pth row module 108 is connected to the first port 1 of the three corresponding IC modules 108-IC of the P+1th row, as shown. Fig.27B . The second port 2 of all three IC modules 108-ICs in the P+1th row is connected to the second port 2 of the ConSource V1 / V2 / V3 module 108 in the Qth row of the system 2750'". The first, second and third output terminals A4, B4 and C4 of the motor 2200'" are connected to the first port 1 of the ConSource V1 / V2 / V3 module in the first row of the system 2750'". The second port 2 of the ConSource V1 / V2 / V3 module 108-1 in the first row is connected to any number of intermediate rows (not shown) in a cascade manner as described herein, up to the first port of the Qth row of all three array columns of the system 2750'".

[0195] The third and fourth ports 3 and 4 of the six IC modules 108-ICs in the N+1th row of system 2750 and the P+1th row of system 2750” are connected together and connected to a first auxiliary load 408. The fifth and sixth ports 5 and 6 of the six IC modules 108-ICs in the N+1th row of system 2750 and the P+1th row of system 2750” are connected together and connected to a second auxiliary load 410. The auxiliary loads 408 and 410 have different voltages and respectively represent, for example, but not limited to, an on-board network system and an air conditioning power supply system of an electric vehicle. Fig.27BThe configuration may be used in a variety of stationary and mobile applications, including a four-wheel EV with four in-wheel motors 2200, 2200', 2200", 2200'" to provide all-wheel drive. The embodiment may be configured such that motors 2200 and 2200" are front wheel motors and motors 2200' and 2200'" are rear wheel motors, or vice versa. Regardless of whether auxiliary loads 408 and 410 are supplied, the embodiment permits inter-phase balancing (e.g., inter-system or inter-pack balancing) within each individual system and between phases across the four systems.

[0196] Fig.28 An example embodiment of a seventh version of a ConSource pack according to the present disclosure including a plurality of ConSource modules 108 connected in a three-dimensional array is shown, the ConSource modules 108 being connected to a three-phase open winding motor 2850 and auxiliary loads 408, 410. In this embodiment, the modules 108 may be segmented into a first system 2800 and a second system 2800'. The systems 2800 and 2800' may operate at similar frequencies but different voltages. If desired, all of the modules 108 shown here may be combined in a single energy pack, wherein the modules 108 are co-located in a single common housing or enclosure. Alternatively, the modules 108 of the system 2800 may be combined in a first pack, and the modules 108 of the system 2800' may be combined in a different second pack.

[0197] The first ports 1 of the ConSource V1 / V2 / V3 modules 108-1 of the first row of all three array columns 2810 are connected together. The second ports 2 of the ConSource V1 / V2 / V3 modules of the first row of all three array columns are connected to the first ports 1 (not shown) of the ConSource V1 / V2 / V3 modules of the second row of all three array columns 2810, and so on further down to the Nth row of each array column in the same order. Fig.28As shown in FIG, the second port 2 of the ConSource V1 / V2 / V3 module 108 of the Nth row of all three array columns is connected to the first, second and third terminals A, B, C of the open winding motor 2850. The first, second and third terminals A', B', C' of the open winding motor 2850 are connected to the first port 1 of the ConSource V1 / V2 / V3 module of the N+1th row of all three array columns. The second port 2 of the ConSource V1 / V2 / V3 module of the N+1th row of all three array columns is connected to the first port 1 of the ConSource V1 / V2 / V3 module of the N+2th row of all three array columns, and so on further down to the Mth row of each array column in the same order. The second port 2 of the ConSource V1 / V2 / V3 module of the Mth row of the first column is connected to the first port 1 of the first additional ConSource V3 module 108-IC of the M+1th row. The second port 2 of the ConSource V1 / V2 / V3 module in the Mth row of the second array column is connected to the second port 2 of the first additional ConSource V3 module 108-IC in the M+1th row. The second port 2 of the ConSource V1 / V2 / V3 module in the Mth row of the third column is connected to the first port 1 of the second additional ConSource V3 module 108-IC in the M+1th row.

[0198] The third and fourth ports 3 and 4 of the two additional ConSource V3 modules in the M+1th row are connected together and connected to the second auxiliary load 410. The fifth and sixth ports 5 and 6 of the two additional ConSource V3 modules in the M+1th row are connected together and connected to the first auxiliary load 408. The first auxiliary load and the second auxiliary load have different voltages and represent, for example but not limited to, an onboard network system and an air conditioning power supply system of an electric vehicle, respectively.

[0199] In addition to about Fig. 22 In addition to the advantages mentioned, Fig.28 This three-phase motor drive embodiment of the system 100 (three-dimensional array) shown in - with two additional interconnected ConSource V3 modules - is suitable for open winding motors and enables efficient and fast energy exchange (phase-to-phase balancing) between all ConSource modules of the system and the phase motors. The additional output terminals 3, 4, 5, 6 of the interconnected ConSource V3 modules provide different levels of low voltage, which can be used to provide power to auxiliary loads, which in turn represent, for example, the electric on-board network and HVAC power lines of an electric vehicle. In this case, no additional low-voltage battery is required; the energy for the system mentioned above is delivered by the entire array of ConSource modules. In Fig.28In an embodiment, all modules may be implemented in a single package, or modules in rows 1 to N may be implemented as a first package, and modules in rows N+1 to M (or M+1) may be implemented as a second package.

[0200] Fig.29 An exemplary embodiment of the eighth version of the ConSource package according to the present disclosure is shown, which includes a plurality of ConSource modules 108 connected in a three-dimensional array and forming two systems 2901 and 2902, connected to two three-phase open winding motors 2850, 2850' and auxiliary loads 408, 410. More specifically, two three-phase subsystems 2900, 2900' are used to drive the motor 2850 and supply the auxiliary loads 408 and 410, while the other two three-phase subsystems 2900", 2900' are used to drive the motor and 2850', and both systems 2901 and 2902 are interconnected with the module 108-IC of the subsystem 2900'. Thus, system 2901 and system 2902 can operate at different voltages and frequencies, while within system 2901, subsystems 2900 and 2900' can operate at similar or equal frequencies but can have different voltages, and within system 2902, subsystems 2900" and 2900'" can operate at similar or equal frequencies but can have different voltages. Fig.29 All modules 108 shown in can be combined in a single package. Alternatively, all modules 108 of system 2901 can be combined in a single package, and all modules 108 of system 2902 can be combined in a different second package. In another embodiment, the modules 108 of each of the four subsystems 2900, 2900', 2900", 2900'" are respectively combined in four separate packages 2705, 2705', 2705", 2705'". Combinations of these different package configurations of systems 2901 and 2902 can also be implemented. In some embodiments, IC modules 108-IC can be combined individually or together in separate and independent packages.

[0201] The first ports 1 of the ConSource V1 / V2 / V3 modules 108-1 of the first row of all three array columns are connected together. The second ports 2 of the ConSource V1 / V2 / V3 modules 108 of the first row of all three array columns are connected to the first ports 1 (not shown) of the ConSource V1 / V2 / V3 modules 108-1 of the second row of all three array columns, and so on further down to the Nth row in the same order. The second ports 2 of the ConSource V1 / V2 / V3 modules 108-N of the Nth row of all three array columns are connected to the first, second and third terminals A1, B1, C1 of the first open winding motor 2850, as shown in FIG. Fig.29. The first, second and third terminals A1', B1', C1' of the first open winding motor 2850 are connected to the first port 1 of the ConSource V1 / V2 / V3 module 108-(N+1) in the N+1th row of all three array columns. The second port 2 of the ConSource V1 / V2 / V3 module 108-(N+1) in the N+1th row of all three array columns is connected to the first port 1 (not shown) of the ConSource V1 / V2 / V3 module in the N+2th row of all three array columns, and so on further down to the Mth row in the same order.

[0202] The second port 2 of the ConSource V1 / V2 / V3 module 108-M in the Mth row of all three array columns of the ConSource pack is connected to the first port 1 of the three corresponding ConSource V3 modules 108-IC in the M+1th row, such as Fig.29 . The second port 2 of all three ConSource V3 modules 108-IC in row M+1 is connected to the second port 2 of the ConSource V1 / V2 / V3 module 108-(M+2) in row M+2. The first port 1 of the ConSource V1 / V2 / V3 module in row M+2 is connected to the second port 2 (not shown) of the ConSource V1 / V2 / V3 module in row M+3, and so on further down to row K in the same order. The first port 1 of the ConSource V1 / V2 / V3 module 108-K in row K of all three array columns is connected to the first, second and third input terminals A2, B2, C2 of the second open winding motor 2850', as shown in FIG. Fig.29 as shown in .

[0203] The first, second and third output terminals A2', B2', C2' of the second open winding motor 2850' are connected to the first port 1 of the ConSource V1 / V2 / V3 module 108-(K+1) in the K+1th row of all three array columns. The first port 1 of the ConSource V1 / V2 / V3 module in the K+1th row of all three array columns is connected to the second port 2 (not shown) of the ConSource V1 / V2 / V3 module in the K+2th row of all three array columns, and so on further down to the Lth row in the same order. The first port 1 of the ConSource V1 / V2 / V3 module in the Lth row of all three array columns is connected together.

[0204] The third and fourth ports 3 and 4 of the two additional ConSource V3 modules in the M+1th row are connected together and connected to the second auxiliary load 410. The fifth and sixth ports 5 and 6 of the two additional ConSource V3 modules in the M+1th row are connected together and connected to the first auxiliary load 408. The first auxiliary load and the second auxiliary load 410 have different voltages and represent, for example but not limited to, an onboard network system and an air conditioning power supply system of an electric vehicle, respectively.

[0205] have Fig.29 This three-dimensional array embodiment of the system 100 of three additional interconnected ConSource V3 modules shown in provides independent voltage and frequency regulation (control) for two independent open winding motors (dual motor drive system) and allows efficient and fast energy exchange (phase balancing) between all ConSource modules and the phases of the two motors of such a dual motor system. The additional output terminals 3, 4, 5, 6 of the interconnected ConSource V3 modules provide different levels of low voltage that can be used to provide power to auxiliary loads, which in turn represent, for example, the electric on-board network and HVAC power lines of an electric vehicle. In this case, no additional low voltage battery is required; the energy for the above-mentioned system is delivered by the entire array of ConSource modules.

[0206] Example Embodiment of Module Control

[0207] Steering Figure 30-40B , illustrates an example system and method for facilitating a control system 100 to provide balancing between ConSource modules in different system configurations. Fig.29 The architecture of the example embodiment shown in enables control of power sharing between ConSource modules. Such control enables maintaining a balance in one or more parameters (such as the SOC of the Energy Sources of the ConSource modules) during discharge, charging, and at rest, which can help utilize the full capacity of each Energy Source regardless of possible differences in capacity. In addition, the balance can be used to equalize the temperature of the Energy Sources and / or other components of the ConSource modules. Temperature balancing increases the power capability of the system 100 and provides more uniform aging of the Energy Sources regardless of their location within the system 100 and differences in thermal resistivity.

[0208] The system 100 may balance the parameters of the modules 108 within a particular phase, which may be referred to as intra-phase balancing, and may balance the parameters of the modules 108 across different phases or a multi-phase (e.g., two or more phases) system, which may be referred to as inter-phase balancing. The control circuit 102 of the system 100 may simultaneously perform intra-phase balancing, inter-phase balancing, utilization of multiple energy sources within a module ( Fig.11)、Active filtering( Figures 12A-12B ) and auxiliary load supply ( Fig.13 ) in any combination.

[0209] Fig.30 An example embodiment of a single-phase AC or DC balance controller 3000 is depicted, which may include a peak detector 3010 ("Peak Detect"), a frequency divider 3020 ("Frequency Divide"), and an intra-phase balance controller 3030 ("Intra-Phase Balance Controller"). The peak detector 3010 detects a peak value Vpk of a reference voltage Vr, which may be specific to the operation and / or balance of the phase controller 3000. The frequency divider generates a normalized reference waveform Vrn by dividing the reference voltage Vr by its detected peak value Vpk. The intra-phase balance controller 3030 uses the peak voltage Vpk along with ConSource state information (e.g., SOCi, Ti, Qi, Vi, etc.) to generate a modulation index Mi for each module within the controlled phase. The single-phase balance controller 3000 may be implemented in hardware, software, or a combination thereof, and may be located as part of an MCD, or may be distributed in part or in whole between the LCDs described herein, or may be a separate controller independent of the MCD and LCD.

[0210] In the case of single-phase AC or DC, or with respect to a single phase of a multi-phase system, a single-phase balancing controller 3000 (e.g., as part of an MCD) receives a reference voltage Vr and collects state information such as state of charge SOCi, temperature Ti, capacity Qi, and voltage Vi from all ConSources of the system 100 (e.g., from the system's LCDs). The controller 3000 uses these signals to generate a modulation index Mi and a normalized reference waveform Vrn, which are then sent to each LCD to generate a switching signal. The reference waveform Vrn may be sent continuously, and the modulation index may be sent at regular intervals, such as once per Vrn cycle. The LCD may modulate or scale the normalized reference voltage Vrn by the received modulation index. In some examples, the modulation index may be a number between zero and one (inclusive). According to information about Figures 14A-14DThe modulated or scaled Vrn may be used as Vref (or -Vref) according to the pulse width modulation technique described, or according to other modulation techniques. In this way, the modulation index may be used to control the PWM switching signal generated by the LCD and provided to the converter switching circuit (e.g., S3-S6 or S1-S6), and thereby adjust the operation of each ConSource module. For example, a ConSource module controlled to maintain normal or full operation may receive a modulation index of one, while a ConSource module controlled to operate less than normal or full operation may receive a modulation index less than one. A ConSource module controlled to stop power output may receive a modulation index of zero. A person of ordinary skill in the art will readily recognize, after reading this specification, that other values ​​of the modulation index may be used to achieve similar functionality.

[0211] The single-phase balancing controller 3000 can generate a modulation index for each ConSource module based on any number of aspects or operating characteristics described herein, such as the state of charge (SOC), temperature (T), capacity (Q), state of health (SOH), voltage (V), and / or current (I) of its energy source, in a manner that promotes the following: the sum of the generated ConSource voltages does not exceed the peak voltage Vpk. For example, Vpk can be the sum of the products of the primary energy source voltages of each module and the modulation index of that module (e.g., Vpk = M1V1+M2V2+M3V3 . . . +M N V N etc.). Different combinations of modulation indices, and hence corresponding voltage contributions made by the modules, may be used, but the overall generated voltage should remain the same. Fig.31 is a phasor diagram depicting the peak voltage 3100 required for a single phase array output, alongside a first example of an output voltage 3100' produced across two opposing terminals A, B of a four module array, where the output voltage 3100' is the superposition of four equal voltage contributions from each of the four modules. Also shown is a second example of an output voltage 3100" where the relative contributions of the four modules are adjusted and are unequal.

[0212] In addition, the controller 3000 can control operation to the extent that it does not prevent the power output requirement of the system from being achieved at any one time (e.g., such as during maximum acceleration of the EV), so that the SOC of the (one or more) energy sources in each module remain balanced or converge to a balanced condition if they are unbalanced, and / or so that the temperature of the (one or more) energy sources or other components (e.g., energy buffers) in each module remain balanced or converge to a balanced condition if they are unbalanced. The power flow into and out of the modules can be adjusted so that the capacity differences between the sources do not cause SOC deviations. The balance of SOC and temperature may indirectly cause some balance of SOH. If desired, the voltage and current can be balanced directly, but in many embodiments, the primary goal of the system is to balance the SOC and temperature, and the balance of SOC can result in a balance of voltage and current in a highly symmetrical system in which the modules have similar capacities and impedances.

[0213] Since it may not be possible to balance all parameters simultaneously (e.g., balancing of one parameter may further unbalance another parameter), a combination of balancing any two or more parameters (SOC, T, Q, SOH, V, I) may be applied, with priority given to any one depending on the application requirements. Priority in balancing may be given to SOC compared to other parameters (T, Q, SOH, V, I), with an exception if one of the other parameters (T, Q, SOH, V, I) reaches a severe unbalance condition beyond the threshold.

[0214] As mentioned, balancing can also be performed in an array-to-array or phase-to-phase manner. For ease of description, embodiments will be described with respect to phase-to-phase balancing. In all embodiments described herein, phase-to-phase balancing can be performed while intra-phase balancing is performed. For example, Fig.32An example embodiment of a three-phase balancing controller 3200 is depicted, which may include one interphase controller 3210 and three intraphase balancing controllers 3220-1, 3220-2, 3220-3 for phases A, B, and C, respectively. The intraphase balancing controller 3220 may be configured or programmed to balance aspects of the ConSource modules within each one-dimensional array, particularly and as an example, within one phase. The interphase balancing controller 3210 may be configured or programmed to balance aspects of the ConSource modules between or across the entire multidimensional array, particularly and as an example, between arrays of different phases or across arrays of different phases. This may be achieved by injecting a common mode (e.g., a neutral point offset) into the phases or by interconnecting modules (common modules), or by both. The controller 3200 may be implemented in hardware, software, or a combination thereof, and may be located as part of the MCD, or may be distributed partially or entirely between the LCDs described herein, or may be a separate controller independent of the MCD and the LCD. The intra-phase balance controllers 3220-1, 3220-2, 3220-3 and the inter-phase balance controller 3210 can each be implemented individually in hardware, software, or a combination thereof, and can be located as part of the MCD, or can be partially or fully distributed between the LCDs described herein, or can be separate controllers independent of the MCD and LCD.

[0215] The reference signal input to the system can be VrA, VrB, VrC, or any combination of two of these signals, or any other transform that can reconstruct these signals, such as the Clarke transform (ie, Vrα, Vrβ).

[0216] Fig.33A and 33B is a phasor diagram depicting a phase diagram for a Y-connected three-phase system with no interconnect (IC) modules between phases A, B, and C (see, for example, Fig.18 and 22 Here, intra-phase balancing can be performed or achieved by controlling the modulation index of the modules within each phase A, B, and C, where each bidirectional arrow indicates the energy contribution of a particular module within each phase (in the example with nine modules, there are three modules in each phase).

[0217] The control circuit (e.g., controller 3200, MCD 112) can perform interphase balancing by adding certain common modes to the phase reference (VrnA, VrnB, VrnC), and the neutral point "N" can be offset from one position to another. The change in the phase reference causes a change in the modulation index of all modules in that phase, which increases or decreases their aggregate contribution to power. For example, after measuring one or more parameters of the modules in each phase (e.g., SOC, T, Q, SOH, V, I), the interphase balancing controller 3210 can determine to adjust the energy output (discharge) or input (charge) to one or more phases. For example, if a determination is made to reduce the energy output of the module in phase A by 10%, a component equal to 10% of VrnA can be subtracted from VrnA, and the same 10% component of VrnA (e.g., common mode) can also be subtracted from VrnB and VrnC, which will shift the neutral point toward A. As mentioned above, this can occur while performing intra-phase balancing.

[0218] For example, in Fig.33B In the example, assuming that the system is discharging and the total energy available in the modules of phase A is less than the total energy available in the modules of phase C, which in turn is less than the total energy available in the modules of phase B, according to similar common-mode techniques, for SOC balance, the neutral point can be obtained from Fig.33A The position is offset to Fig.33B , as shown at 3310. This reduces the contribution of phase A, and to a lesser extent phase C, and increases the contribution of phase B to compensate. This provides control over the energy output share of each phase to establish the three-phase voltage.

[0219] Fig.34A and 34B is a phasor diagram depicting a phase diagram for a Y-connected three-phase system with interconnect (IC) modules between phases A, B, and C (see, for example, system 100, Fig. 20 and 24 Here, intra-phase balancing can again be achieved by controlling the modulation index of the modules within each phase array as described above. Inter-phase balancing, for example, controlled overall by controller 3200, can be performed by selectively applying energy from one or more IC modules to one or more phase arrays, which can be referred to as inter-phase energy injection. This is in Fig.34A , where the fourth contribution (with Fig.33A ) has been added in the center of the phasor diagram.

[0220] Fig.34AAn example is shown in which the system is discharging and the total energy available in the three modules of phase A (SOC) is less than the total energy available in the three modules of phase C, which in turn is less than the total energy available in the three modules of phase B (SOC A < SOC C < SOC B Controller 3200 may supply or output a modulation index to the IC module of phase A that is greater than the modulation index of the IC module of phase B (which may be the same or a different IC module), which in turn is greater than the modulation index of the IC module of phase C (which may be the same or a different IC module as the IC modules of A and B) (M IA > M IC > M IB ). The modulation index of the non-interconnected modules within each phase can be reduced accordingly, and thus the contribution of the non-interconnected modules of phase B is greater than the contribution of the non-interconnected modules of phase C, which in turn is greater than the contribution of the non-interconnected modules of phase A, which moves the system towards a balanced SOC in all phases. Similar methods can be used to balance one or more of the other parameters (T, Q, SOH, V, I).

[0221] In systems with IC modules between phases, inter-phase balancing can also be performed by neutral point shifting (or common mode injection) as described above. Fig.34B An example is depicted where in a system with IC modules using both common mode injection and inter-phase energy injection, inter-phase balancing is performed by controller 3200. Such a combination allows for more robust and flexible balancing over a wider range of operating conditions.

[0222] The system 100 can determine an appropriate environment in which phase balancing is performed using neutral point offset alone, phase energy injection alone, or a combination of both. Neutral point offset can be performed using energy from all modules of each phase array, while phase energy injection can be performed using energy from only one or more IC modules. Therefore, neutral point offset has a wider range of available energy to cover more different phase imbalances. There may be embodiments in which the system 100 is supplying auxiliary loads or other systems in which neutral point offset is not desirable, and in some cases, neutral point offset may increase the phase shift between the voltage and current of the phase array, which may increase DC second-order harmonics. Phase energy injection allows balancing without neutral point offset, and these potential side effects can be avoided. In some embodiments, the control circuit 102 (e.g., controller 3200, MCD 114) can use phase energy injection for relatively small or minor phase imbalances, and can use neutral point offset (alone or with phase energy injection) for relatively large or severe phase imbalances and / or phase imbalances that need to be balanced in a short period of time. In these embodiments, the control circuit 102 can be configured to evaluate or determine the degree of phase imbalance and compare it to a threshold (e.g., SOC, temperature) that distinguishes between relatively small and relatively large phase imbalances (or other conditions that govern which technique to use), and perform phase balancing using only phase energy injection for small differences and neutral point shifting for relatively large differences, or a combination of both.

[0223] Fig.35A and 35B is a phasor diagram depicting example embodiments 3500 and 3500' of a control technique for a four-phase system without and with IC modules, respectively, between phases A, B, C, and D. Here, intra-phase balancing may be achieved by controlling the modulation index of the modules within each of phases A, B, C, and D. Inter-phase balancing may be achieved by neutral point offset and / or by controlling the contribution of interconnected modules to each phase (inter-phase energy injection) where applicable.

[0224] Fig.36A and 36B 3600 and 3600' are phasor diagrams depicting example embodiments of control techniques for a five-phase system without and with IC modules, respectively, between phases A, B, C, D, and E. Here, intra-phase balance may be achieved by controlling the modulation index of the modules within each of phases A, B, C, D, and E. Inter-phase balance may be achieved by neutral point offset and / or by controlling the contribution of interconnected modules to each phase (inter-phase energy injection) where applicable.

[0225] Fig.37Aand 37B is a phasor diagram that depicts the phases for phases A, B, C, D, E, and F without and with IC modules (e.g., reference Fig.26 Here, intra-phase balancing can be achieved by controlling the modulation index of the modules within each of phases A, B, C, D, E, and F. Inter-phase balancing can be achieved by neutral point offset and / or by controlling the contribution of interconnected modules to each phase (inter-phase energy injection) where applicable.

[0226] In the system 100 described with respect to FIG. 27 , two three-phase systems 2700 and 2700 ′ are shown, which can be discharged and charged with different voltages and frequencies. The intra-phase balancing of these systems can be achieved by controlling the modulation index of the modules 108 within each phase A, B, C, A′, B′, C′. The inter-phase balancing within each system 2700 and 2700 ′ and between the two systems can be achieved by controlling the voltage contribution of the IC modules 108-IC to each phase. Fig.38A The phasor diagrams of FIG. 3810 and 3820 depict examples of phase balancing as applied to systems 2700 and 2700', respectively, with IC modules 108-IC, for example, where N is 3. Phase balancing within each system 2700 and 2700' may alternatively or additionally be achieved by neutral point offset, such as Fig.38B As shown in Examples 3810 and 3820.

[0227] In About Fig.28 In the described system 100, two three-phase systems 2800 and 2800' are described, which discharge at similar frequencies but may have different voltages. The balance of the systems 2800 and 2800' is respectively about Fig.39A and 39B Examples 3900 and 3900' are described in (eg, where N=2 for system 2800 and MN=3 for system 2800'). Fig.39A In the embodiment, since the complementary phases in the two systems 3900, 3900' work in pairs to generate voltage across each motor winding, the modules 108 in the phase pairs (e.g., A and A', B and B', C and C') can be considered for intra-phase balancing. For example, to establish a certain voltage between A and A', all modules 108 in the A and A' phases can contribute proportionally according to their state information. Fig.39A As shown in , the phase balance, or in this case the balance between phase pairs, can be achieved by interconnecting the modules 108-IC. The phase balance within each system 2800 and 2800' can be achieved alternatively or additionally by neutral point offset, such as Fig.39B As shown in Examples 3900 and 3900'.

[0228] In About Fig.29 In the depicted system 100, system 2901 and system 2902 may operate at different voltages and frequencies. Within system 2901, subsystems 2900 and 2900' may operate at similar or equal frequencies, but may have different voltages; and within system 2902, subsystems 2900" and 2900'" may operate at similar or equal frequencies, but may have different voltages. The balance of systems 2900, 2900', 2900", 2900'" respectively is about Fig.40A and 40B 4000, 4010, 4020, 4030 are described in (e.g., where each system 2900, 2900', 2900", and 2900'" has 3 rows of modules 108, excluding IC module 108-IC). Fig.40A In the embodiment, since the complementary phases in the four systems 4000, 4010, 4020, 4030 work in pairs to generate voltage across each motor winding, the modules 108 in the phase pairs (e.g., A1 and A1', B1 and B1', C1 and C1', A2 and A2', B2 and B2', C2 and C2') can be considered for intra-phase balancing. For example, in order to establish a certain voltage between A1 and A1', all modules 108 in the A1 and A1' phases can contribute proportionally according to their state information.

[0229] like Fig.40A As shown in , the phase balance, or in this case the balance between phase pairs, can be achieved by the interconnect modules 108-IC of 4010 and 4030. The phase balance within each system 2900, 2900', 2900" and 2900"' can be achieved alternatively or additionally by neutral point offset, such as Fig.40B as shown in the example.

[0230] Additional Example Embodiments of IC Modules

[0231] The interconnect (IC) module can be used for either or both phase balancing and auxiliary load supply. In addition to being usable as a standard module level within a phase (e.g., one of N modules), the ConSource module V3 is shown and described as being usable as an IC module 108-IC capable of both phase balancing and auxiliary load supply (e.g., see the Figure 4 , 17 , 20, 21, 24-29 described exemplary embodiments). The IC module may also be implemented in other configurations, including Figure 2 and Figure 3configuration, where the module outputs (out1 and out2) are connected to separate module arrays operating in different phases. The IC module may include any number of one or more energy sources, optional energy buffers, switching circuits for supplying energy to one or more module arrays and / or supplying power to one or more auxiliary loads, may include control circuits (e.g., local control devices), and may include measurement circuits (e.g., one or more circuits and / or sensors) for measuring various parameters about the IC module itself or its various loads (e.g., SOC of an energy source, temperature of an energy source or energy buffer, capacity of an energy source, SOH of an energy source, voltage and / or current measurements associated with the IC module, voltage and / or current measurements associated with (one or more) auxiliary loads, etc.).

[0232] Fig.41A 1 is a block diagram depicting an example embodiment of system 100, wherein IC module 108-IC is configured to be used in phase balancing between arrays 1500-A, 1500-B, and 1500-C of phases A, B, and C, respectively. IC module 108-IC may be configured according to any of ConSource module embodiments V1, V2, or V3. IC module 108-IC may selectively connect one or more energy sources of module 108-IC to one or more of arrays 1500-A, 1500-B, and 1500-C, or have no output. System 100 may be controlled by control circuit 102 (not shown, see Figure 1A ) control. Array 1500-A outputs an AC voltage waveform at node A (VoutA), array 1500-B outputs an AC voltage waveform at node B (VoutB), and array 1500-C outputs an AC voltage waveform at node C (VoutC).

[0233] Fig.41B 1 is a schematic diagram depicting an example embodiment of an IC module 108-IC having an energy source 202 coupled to a switching circuit 132. As described with respect to switching circuits 207 and 208, the switching circuit 132 can be configured in any arrangement suitable for the application requirements and with any switch type (e.g., MOSFET, IGBT, Silicon, GaN, etc.). The switching circuit 132 has outputs 133-1, 133-2, and 133-3 coupled to the modules of each of the arrays 1500-A, 1500-B, and 1500-C. In other embodiments, the IC module 108-IC can be coupled to a system having only two phases, in which case only two outputs 133 are necessary. Similarly, the IC module 108-IC can be scaled up with additional switching circuits and outputs to couple to a system having more than three phases.

[0234] refer to Fig.41A and41B , the three arrays 1500 are electrically positioned between the IC module 108-IC and the outputs A, B, C to the load. In other words, the array 1500-A has a first terminal A for connecting to the load and a second terminal (positioned opposite the first terminal on the opposite end of the array 1500-A) for connecting to the output 133-1 of the IC module 108-IC. Similarly, the array 1500-B and the array 1500-C each have first terminals B and C, respectively, for connecting to the load, and second terminals for connecting to the outputs 133-2 and 133-3, respectively, of the IC module 108-IC. Positioning the IC module 108-IC in this manner allows, among other things, the IC module to control the current routing between each of the three-phase arrays 1500-A, B, and C.

[0235] In this embodiment, the switch circuit 132 is implemented with three switch sections 134-1, 134-2, and 134-3, each of which is coupled to a corresponding output 133. Each switch section 134 can be controlled by a control circuit (e.g., control circuit 102, see FIG. 104 ) via one or more control input lines 136. Figure 1A The control circuit may control the switch circuit 132 according to any desired control technique, including the PWM and hysteresis techniques mentioned herein.

[0236] exist Fig.41B In the example of FIG. 1 , the control circuit 102 is implemented as an LCD 114 and an MCD 112 (not shown). The LCD 114 is associated with the IC module 108-IC and can receive monitoring data (e.g., SOC of ES1, temperature of ES1, Q of ES1, etc.) from the IC module 108-IC, which is from a sensor or other measurement device or circuit (not shown) coupled to the module 108-IC. The monitoring data and / or other data derived from the monitoring data can be output to the MDC 112 for use in system control as described herein. The LCD 114 can also receive timing information (not shown) for the purpose of synchronizing the modules of the system 100. One or more carrier signals (not shown), such as a sawtooth signal ( Fig.14A , 14B ) may also be received by LCD 114 or generated internally by LCD 114.

[0237] The switch sections 134 may each be implemented as a half-branch having switches S7 and S8, which may be selectively controlled by the LCD 114 via control input lines 136-1 to 136-6. (Switches S7 and S8 may be the same as switches S3 and S4 (or S5 and S6) described earlier). For phase balancing, energy from the energy source 202 may be supplied to either or both phase arrays 1500 over time using the switch sections 134. Supplying supplemental energy to one or both phase arrays allows the energy output of the cascaded modules 108-1 to 108-N of those supplied phase arrays to be reduced relative to the phase array(s) not supplied.

[0238] For example, in some example embodiments where PWM is applied, the LCD 114 may be configured to receive a normalized voltage reference signal (Vrn) (from the MCD 112) for each of the one or more phase arrays to which the IC module 108-IC is coupled, which in this example are all three: VrnA, VrnB, VrnC. The LCD 114 may also receive the modulation index MiA, MiB, MiC of the switch sections 134-1, 134-2, 134-3 of each phase array, respectively, from the MCD 112. The LCD 114 may modulate (e.g., multiply) each corresponding Vrn with the modulation index of the switch section directly coupled to the phase array (e.g., VrnA multiplied by MiA), and then generate the control signal(s) for each switch section 134 using the carrier signal. In other embodiments, the MCD 112 may perform the modulation and output the modulated voltage reference waveform for each section 134 directly to the LCD 114. In still other embodiments, all processing and modulation may be performed by a single control entity, which may output control signals directly to each portion 134 .

[0239] This switching may be modulated so that power from energy source 202 is supplied to the array(s) at appropriate intervals and durations.Such method techniques may be implemented in a variety of ways.

[0240] In one example embodiment, regarding Figures 14A-14D The PWM method described is applied to Fig.41A and 41B An embodiment in which the switch circuit 207 of each module 108-1 to 108-N is configured as an H-bridge ( Figure 5A). For the example case where there are four cascade stages (N=4) plus the IC module 108-IC in each array 1500, nine carrier signals (2N+1) that are equally offset in phase angle are used to generate control signals. Eight of the nine carrier signals are used to generate control signals for each of the four modules 108-1 to 108-4 of the particular array 1500 (e.g., one carrier for S3 and S4, and one carrier for S5 and S6 per module), and the ninth carrier may be used to generate control signals for the switching portion 134 of the IC module 108-IC. Thus, each AC output waveform (Vout) may be an eleven-level waveform with a first level at zero volts, eight levels may be generated by the four cascade modules 108-1 to 108-4, and two levels may be generated by the IC module 108-IC ( Fig.41B The +V IC and -V IC ). (The energy source 202 of the IC module 108-IC is preferably the same standard voltage as the energy source of the cascaded modules, although this is not required.).

[0241] During balancing operation, the modulation index of each switch section 134 may be set at a value that causes the same or similar amount of net energy to be supplied to each array 1500 by the energy source 202 and / or the energy buffer 204. For example, the modulation index for each switch section 134 may be the same or similar and may be set at a level or value that causes the (one or more) IC modules to perform a net or time-averaged discharge of energy to the one or more arrays 1500 during balancing operation, so as to dissipate the (one or more) IC modules at the same rate as other modules in the system. In some embodiments, the modulation index for each switch section 134 may be the same or similar and may be set at a level or value that does not cause a net or time-averaged discharge of energy (so that the net energy discharge is zero) during balancing operation. This may be useful in situations where the (one or more) IC modules may be dissipated below the level of other modules and continued operation of the other modules is required without dissipating the (one or more) IC modules in order to achieve similar SOC levels across the entire system 100. For example, this may occur if the EV supplies power to an auxiliary load for an extended period of time without driving.

[0242] When an unbalanced condition occurs between the arrays 1500, the modulation index of the system 100 can be adjusted so that the system converges back to a balanced condition. For example, the control circuit 102 can detect that one of the arrays 1500 has a relatively lower SOC parameter than the other arrays (e.g., the sum of the total SOC of the cascaded modules 108-1 to 108-4). The control circuit 102 can then cause the IC modules 108-IC to discharge more to the low array than the other arrays, and can also cause the cascaded modules of the low array to discharge relatively less (e.g., on a time average basis). The relative net energy contributed by the IC modules 108-IC is increased compared to the modules of the assisted array, and also compared to the amount of net energy contributed by the IC modules to the other arrays. This can be accomplished by increasing the modulation index of the switching portion of the IC modules supplying the low array and decreasing the modulation index of one or more cascaded modules of the low array in a manner that maintains the Vout of the low array at an appropriate or desired level, and keeping the modulation index of the other switching portions 134 supplying the other phase arrays relatively unchanged. The following is about Figures 42A-42B Additional example embodiments utilizing inter-phase balancing of IC modules are described.

[0243] IC module 108-IC may also be scaled to supply current to one or more phases of a first system or package and one or more phases of a second system or package (see, e.g., Fig.27A , 27B 1 and 29 of the IC module 108-IC). For example, the first switch portion 134-1 of the IC module can be coupled to the phase array of the first package, and the second switch portion 134-2 of the IC module can be coupled to the phase array of the second different package. The first package can have multiple arrays that provide a multi-phase supply to the first motor, and the second package can have multiple arrays that provide a multi-phase supply to the second motor (e.g., as Fig.27A , 27B 29). For inter-pack balancing, energy from the IC module can be supplied to the two-phase arrays of different packs over time using switch sections 134-1 and 134-2. The system can be scaled so that each IC module supplies two arrays - one array from each pack, so three IC modules are needed for two three-phase packs (e.g. Fig.27A , 27Band 29), or each IC module supplies more than two arrays, up to and including all arrays of two packages (e.g., one IC module couples all three arrays of a first three-phase package and all three arrays of a second three-phase package). The control circuitry can monitor relevant parameters of the arrays of different components (e.g., state of charge and temperature) and adjust the energy output of the IC modules to compensate for imbalances between arrays or phases of different components in the same manner as described herein to compensate for imbalances between arrays or phases of the same component. In all cases with multiple IC modules, the energy sources can be coupled together in parallel to share energy as described herein.

[0244] The IC module 108 -IC may also be configured to supply power to one or more auxiliary loads 408 (at the same voltage as the energy source 202 ) and / or one or more auxiliary loads 410 (at a voltage stepped down from the energy source 202 ). Fig.41C is a block diagram depicting an example embodiment of a system 100 similar to Fig.41A 1 , but with IC module 108 -IC supplying auxiliary loads 408 , 410 - 1 , and 410 - 2 . Fig.41D 1 is a schematic block diagram depicting this example embodiment of the system 100, focusing on the IC module 108-IC having the energy source 202 coupled to the switching circuit 132. Here, the control circuit 102 is again implemented as an LCD 114 and an MCD 112 (not shown). The LCD 114 can receive monitoring data (e.g., SOC of ES1, temperature of ES1, Q of ES1, voltage of auxiliary load 410, etc.) from the IC module 108-IC and can output this monitoring data and / or other monitoring data to the MDC 112 for use in system control as described herein. In this embodiment, the switching circuit 132 is configured to provide phase balancing capabilities and also supply auxiliary loads 408, 410-1, and 410-2. The switching circuit 132 is implemented with two additional switching sections 208-1 and 208-2, which can have many different configurations. Here, the sections 208-1 and 208-2 each include switches S1 and S2, and are therefore configured as described with respect to Figure 5B The switch section 208-1 has a circuit coupled to the inductor L C1 The output of the inductor L C1 The switch portion 208-2 is coupled to the inductor L C2 The output of the inductor L C2 The switching portions 208 - 1 and 208 - 2 may be controlled by the LCD 112 having one or more control lines 136 .

[0245] Based on LC1 and L C2 The auxiliary loads 410-1 and 410-2 can be operated at different voltages depending on the inductance and the duty cycle applied to the switch portions 208-1 and 208-2. For example, if the energy source 202 operates at 48V, then the auxiliary load 408 can also operate at 48V, the auxiliary load 410-1 can operate at 24V, and the auxiliary load 410-2 can operate at 12V. One of ordinary skill in the art will recognize from this disclosure that embodiments can operate at almost unlimited different voltages and voltage combinations. A voltage and / or current monitoring circuit (not shown) can monitor the voltage and / or current supplied to the auxiliary loads 410-1 and 410-2, and then feed it back to the LCD 114 as monitoring data from the module. The LCD 114 can use this data to control the duty cycle of the switch portions 208-1 and 208-2, and thereby independently adjust the voltage supplied to the loads 410-1 and 410-2.

[0246] To increase the power supply capability of the IC modules 108-IC, the energy source 202 may be configured to have a higher capacity than the energy source of the module 108. For example, in one embodiment, where one of the IC modules applies energy to three phase arrays, and the IC module of each phase array outputs approximately half the energy of the modules in that phase array, the IC module preferably has a capacity that is 1.5 times greater than the modules in the phase array (assuming those modules have the same capacity), thereby allowing the IC module to discharge at the same rate as the modules in the phase array itself. If the IC module also supplies auxiliary loads, an even greater capacity may be desired, such as twice the capacity of the modules in the phase array, in order to permit the IC module to discharge at the same rate relative to the other modules after supplying the auxiliary loads. Alternatively, or in addition to the higher capacity, the IC modules 108-IC may be connected such that the energy sources 202 of more than one or all of the IC modules 108-IC are connected in parallel, as described and illustrated herein with respect to the ConSource module V3 108-IC (see, e.g., with respect to Figure 4 , 20 , 21, and 24-29). In those examples, placing the energy sources in parallel essentially doubles the capacity and permits the IC module to discharge at relatively the same rate as other modules in the system while also supplying auxiliary loads.

[0247] Fig.41E is a block diagram depicting an example embodiment of a system 100 similar to Fig.25100, but without showing loads or motors. Here, two IC modules are implemented: 108-IC-1 and 108-IC-2, where module 108-IC-1 is coupled to phase arrays 1500-A and 1500-B, and where module 108-IC-2 is coupled to phase array 1550-C. Both modules 108-IC supply auxiliary loads 408 and 410. Fig.41F yes Fig.41E Schematic diagram of a system focusing on two IC modules 108-IC and their LCDs 114, wherein module 108-IC-1 is implemented as a ConSource V3 module 108-IC, and module 108-IC-2 is implemented as a ConSource V3 module 108-IC, but without the second switch portion 134 (e.g., Figure 5B Here, each module 108-IC-1 and 108-IC-2 includes a switch circuit 208 and a coupled inductor LC to supply an auxiliary load 410, thereby doubling the current carrying capacity.

[0248] The use of two or more IC modules 108-IC with energy sources 202 connected in parallel (as shown here via connections to nodes 3 and 4 of each module) enables energy to be exchanged between the modules and enables both to operate under relatively balanced conditions. In other words, the energy source 202 of the IC module 108-IC-1 will remain at the same or similar charge level as the energy source 202' in the second IC module 108-IC-2. As the current in each phase changes polarity, each energy source 202 can potentially be continuously charged by the current incoming from one or more phases operating at negative polarity at the time. In a configuration with multiple IC modules, the energy source 202 of each IC module 108 preferably has the same capacity, although this is not required, and in some embodiments, the IC modules may have different capacities. Similarly, the energy source 202 of the IC module may have the same capacity as the cascaded module in each array, so that the discharge rate is generally the same. But in other embodiments, it may have different capacities. In addition, in other embodiments, the energy sources of multiple IC modules 108-IC may be coupled in series rather than in parallel.

[0249] Additional Example Embodiments of Phase Balancing with IC Modules

[0250] Figures 42A-42Bis a flowchart depicting an example embodiment of a method for performing phase balancing in a system 100 having at least one IC module 108-IC. The system can have any configuration or topological arrangement of the modules 108 or other modules described herein, and can supply (or store) energy for or from any number of two or more phases. The balanced arrays can supply the same load or motor, or can be in different systems or packages supplying different loads or motors (e.g., inter-system or inter-package balancing). Because the switching circuits of all modules tend to operate at relatively high frequencies according to PWM and hysteresis techniques, the references to energy output by the modules (e.g., increase, decrease, or remain unchanged) are across time, for example, on a time average or net basis. These references to energy output can also be expressed as cumulative or aggregated energy over a period of time (e.g., over multiple consecutive cycles of the output waveform).

[0251] Fig.42A A method 4200 is shown. At 4202, the control circuit 102 may determine or evaluate whether an unbalanced condition sufficient to invoke inter-phase balancing exists between at least two different arrays 1500. This determination may be based on a wide range of one, two, or more types of qualitative or quantitative information (e.g., measurements or characterizations) communicated to the control circuit (e.g., collected by an LCD and communicated to an MCD). The following paragraphs describe several non-limiting examples of these different types applicable to all embodiments described herein.

[0252] The imbalance condition may be related to energy or charge in the array, such as a SOC parameter (e.g., measurement) of one array or a SOC parameter characterizing one array being less than, greater than, or substantially different than the SOC value of at least one different array or the system as a whole. The SOC parameter may be, for example, the total SOC of all modules in the array, a central trend value (e.g., mean or median) of the SOC of all modules in the array, the SOC of one or more modules in the array, a rate of change of SOC in one or more modules in the array, and the like.

[0253] The imbalance condition can be related to the temperature in the array, such as a temperature parameter of one array or a temperature parameter characterizing one array being less than, greater than, or substantially different from a temperature parameter of at least one different array or the system as a whole. The temperature parameter can be, for example, a central tendency value (e.g., mean or median) of the temperature of all modules in the array, the temperature of one or more modules in the array, the rate of change of temperature of one or more modules in the array, and the like.

[0254] The imbalance condition may be related to capacity (Q) in the array, such as a capacity parameter of one array or a capacity parameter characterizing one array being less than, greater than, or substantially different than a Q parameter of at least one different array or the system as a whole. The Q parameter may be, for example, a central tendency value (e.g., mean or median) of Q for all modules in the array, Q for one or more modules in the array, a rate of change of Q in one or more modules in the array, and the like.

[0255] The imbalance condition may be related to a state of health (SOH) in the array, such as an SOH parameter of one array or a parameter characterizing the SOH of one array being less than, greater than, or substantially different from a SOH parameter of at least one different array or the system as a whole. The SOH parameter may be, for example, a central tendency value (e.g., mean or median) of the SOH of all modules in the array, the SOH of one or more modules in the array, a rate of change of the SOH of one or more modules in the array, and the like.

[0256] The unbalanced condition may be related to the voltage in the array, such as a voltage parameter of one array or a voltage parameter characterizing one array being less than, greater than, or substantially different from a voltage parameter of at least one different array or the system as a whole. The voltage parameter may be, for example, a central trend value (e.g., mean or median) of the current and voltage levels of all modules in the array, a current and voltage of one or more modules in the array, a rate of change of voltage of one or more modules in the array, and the like.

[0257] The unbalanced condition may be related to current in the array, such as a current parameter of one array or a current parameter characterizing one array being less than, greater than, or substantially different from a current parameter of at least one different array or the system as a whole. The current parameter may be, for example, a central trend value (e.g., mean or median) of the current level of all modules in the array, the current of one or more modules in the array, a rate of change of current of one or more modules in the array, and the like.

[0258] An unbalanced condition may also be a fault or degradation condition that limits or prevents the operation or performance of a module in the array, as such a fault or degradation may result in an unbalanced condition across all types of measurements and characterizations.

[0259] As described above, determining or evaluating whether the two arrays are in an unbalanced condition can be relative. The relative difference can be characterized in terms of a comparison fraction or percentile, or in terms of standardized units (e.g., coulombs, temperature, volts, amperes, etc.). The system can be configured to call phase balancing based on any desired amount or threshold of relative difference, where a smaller relative threshold (e.g., 1%) will call phase balancing more frequently than a larger relative threshold (e.g., 5%). The determination or evaluation of whether the two arrays are in a sufficiently unbalanced condition can be based on absolute or non-relative values, for example, if the first array has a value below an absolute threshold (highest temperature, lowest SOC, etc.), it can be determined that an unbalanced condition exists, regardless of what value (one or more) other arrays have (one or more). Determining whether the two arrays are in an unbalanced condition can be based on both relative and absolute factors, for example, the temperature of the first array may exceed a relative threshold difference (e.g., a relative difference of 3 degrees Celsius (C)) compared to the second array, but phase balancing will not be performed until both arrays exceed a minimum absolute temperature (e.g., 12 degrees C) to start phase balancing.

[0260] Return to reference Fig.42A If the control circuit determines that the unbalanced condition requirement is met, the method 4200 proceeds to step 4206 (as indicated at 4204). If the requirement is not met, the method 4200 returns to step 4202. When the system 100 is operating to continuously or repeatedly monitor for the occurrence of an unbalanced condition, this reversal loop may continue indefinitely.

[0261] At step 4206, the control circuit causes supplemental net energy to be supplied from the energy source of the IC module 108-IC to the appropriate array 1500 of modules 108-1 to 108-N. The appropriate array is an array that requires additional energy to offset the unbalanced condition. In some embodiments, this step may include a control circuit causing a reduction in energy supplied from one or more of the cascaded arrays of modules 108-1 to 108-N, wherein the reduction is equivalent to the supplemental energy added by the IC module 108-1, thereby allowing the system 100 to meet the load requirements. The control circuit may determine or estimate the amount of energy output adjustment required by the modules 108-1 to 108-N and the module 108-IC in order for the array to begin to converge back to a balanced condition. The amount of supplemental energy may be an increment over the amount (zero or non-zero) supplied by the IC module 108-IC in a balanced operating state occurring prior to step 4206. Return to Reference About Figures 41A-41BIn the example described, where N=4, in the case of a sample where the array 1500-A needs to be replenished by the IC module 108-IC, then the MCD 112 can determine the amount to reduce the modulation index of all modules 108-1 to 108-4 of the array 1500-A, and the amount to increase the modulation index of the switching section 134-1, to meet the load requirements and make the array converge towards an equilibrium condition over time. These modulation indices can be transmitted to the LCD 114, which can then modulate VrnA for all modules 108-1 to 108-4 and for the switching section 134-1, and generate control signals 136 for each using the modulation waveform.

[0262] After adjusting the relative energy output at 4206, the control circuit may again determine or evaluate whether the unbalanced condition persists at 4208. If the condition persists, the method may return to step 4206 and supplemental energy may be supplied again by the IC module 108-IC as described above (as indicated by 4210). If the unbalanced condition requirement is not met, the method 4200 may proceed to step 4212, where the supplemental supply of energy from the IC module 108-IC may be stopped. This may include reversing to the modulation index used before entering the unbalanced condition (for IC module 108-IC and modules 108-1 to 108-4 of 1500-A), such as reversing to the modulation index of the balanced condition. Alternatively, this may include a decrease in the modulation index of the switch portion 134-1 and an increase in the modulation index of the cascaded modules 108-1 to 108-N, to values ​​that are not necessarily the same as the values ​​used in the previous balanced operation.

[0263] Fig.42B is a flow chart depicting another example embodiment of a method 4220 for phase-to-phase balancing in a system having at least one IC module 108-IC. The method 4220 is similar to the method 4200, except that the phase-to-phase balancing is performed by reducing the energy supplied to the array by the IC module 108-IC. In this example embodiment, the IC module 108-IC contributes energy or power to each array 1500 during a balanced condition. Steps 4222 and 4224 are similar to steps 4202 and 4204 of the method 4200. At 4222, the control circuit 102 may determine or evaluate whether there is an unbalanced condition sufficient to invoke phase-to-phase balancing between at least two different arrays 1500. If the unbalanced condition requirement is met, the method 4220 proceeds to step 4226 (as indicated by 4224). If the requirement is not met, the method 4220 returns to step 4222. When the system 100 is operating to continuously or repeatedly monitor for the occurrence of an unbalanced condition, the reversal loop may continue indefinitely.

[0264] At step 4226, the control circuit causes a decrease in energy output from the IC modules 108-IC to the array having a larger operating margin (e.g., having a higher overall SOC), rather than using the IC modules 108-IC to increase energy output to the array (e.g., having a lower overall SOC). This step may include the control circuit causing an increase in energy supplied from one or more of the cascaded array of modules 108-1 through 108-N in the array with a larger margin, wherein the increase is equivalent to a decrease in energy supplied to the array by the IC modules 108-IC, thereby allowing the system 100 to meet the load requirements. The control circuit may determine or estimate the amount of energy output adjustment required by the adjusted modules 108-1 through 108-N and module 108-IC so that the array begins to converge back to a balanced condition. Return to Reference About Figures 41A-41B In the example described, where N=4, in the sample case where array 1500-A has a relatively greater overall SOC than arrays 1500-B and 1500-C, then MCD 112 can determine an amount to increase the modulation index of all modules 108-1 to 108-4 of array 1500-A, and an amount to decrease the modulation index of switch portion 134-1 supplying array 1500-A, to meet the load requirements and cause array 1500-A to converge with arrays 1500-B and 1500-C toward an equilibrium condition over time. These modulation indices can be transmitted to LCD 114, which can then modulate VrnA for all modules 108-1 to 108-4 and for switch portion 134-1, and generate control signals 136 for each using the modulation waveform.

[0265] After adjusting the relative energy outputs at 4226, the control circuitry may again determine or evaluate whether the unbalanced condition persists at 4228. If the condition persists, the method may return to step 4226 as described above (as indicated at 4230). If the unbalanced condition requirement is not met, the method 4200 may proceed to step 4232, where the reduction of the energy supply from the IC module 108-IC may be stopped. This may include reversing to the modulation index used before entering the unbalanced condition (for the IC module 108-IC and the modules 108-1 to 108-4), for example, to the modulation index of the balanced condition. Alternatively, this may include an increase in the modulation index of the switch portion 134-1 and a decrease in the modulation index of the cascaded modules 108-1 to 108-N of the array 1500-A, to values ​​that are not necessarily the same as the values ​​used in the previous balanced operation.

[0266] about Fig.42A and 42BThe described embodiments may also be combined to compensate for any unbalanced conditions described herein. For example, in the case where array 1500-A has a lower overall SOC than array 1500-B, the energy or power supplied by the IC modules of array 1500-A may be increased, and the energy or power output of one or more cascaded modules 108 of the array 1500-A may be correspondingly reduced. At the same time, the energy or power supplied by the IC modules of array 1500-B may be reduced, and the energy or power output of one or more cascaded modules 108 of the array 1500-B may be correspondingly increased.

[0267] The interconnection of the array 1500 through one or more IC modules 108-IC enables efficient and rapid exchange of energy between multiple phases of the array 1500. For example, current delivered into the system 100 from one of nodes A, B, or C can be used to charge energy sources within one or more modules 108-IC, and those energy sources can be used to selectively discharge one or more of the nodes A, B, and C.

[0268] Example embodiments related to layout and housing

[0269] In many embodiments herein, the ConSource module is shown or described as being separate from the LCD. However, in any and all embodiments described herein, the ConSource module can be configured so that the LCD is a component thereof. For example, Fig.43A is a block diagram depicting an example embodiment of a converter-source module 108 (which may also be referred to as a ConSource module V1, V2, or V3). In this embodiment, the module 108 has an LCD 114 that houses the module 108, as well as a common housing or physical package 4302 for the converter V1 or V2 206, 308, the energy buffer 204, and the energy source 1 202 (and optionally the energy source 2 304, if present). Thus, in this embodiment, the module 108 is provided or manufactured as an integrated or unified device or subsystem.

[0270] Fig.43Bis a block diagram depicting another example embodiment of a converter-source module 108. In this embodiment, the module 108 has a housing or physical package 4303 that houses the LCD of the module 108 as well as the converter V1 or V2 206, 308 and the energy buffer 204. The energy source 1 202 (and optionally the energy source 2 304, if present) are disposed in a separate housing 4304. The housings 4303 and 4304 may be physically joined, secured or connected together prior to installation in the system 100, or may be separate entities that are electrically connected together. The housings 4303, 4304 may have ports or other access points to accommodate electrical connections between the various devices 114, 206, 308, 202, etc.

[0271] Fig.43C is a block diagram depicting another example embodiment of a converter-source module 108. In this embodiment, the module 108 has a first housing or physical package 4306 that holds the LCD 114 of the module 108, and a second housing or physical package 4308 that holds the converter V1 or V2 206, 308 and the energy buffer 204. The energy source 1 202 (and optionally the energy source 2 304, if present) are disposed in a separate housing 4304. The housings 4306, 4308, and 4304 may be physically joined, secured, or connected together prior to installation in the system 100, or may be separate entities that are electrically connected together. All of the housings 4306, 4308, and 4304 may have ports or other accesses to accommodate electrical connections between the various devices 114, 206, 308, 202, etc.

[0272] In any and all embodiments described herein, various circuit components may be integrated on one or more substrates to reduce the form factor. Figures 43A-43C As described, the LCD may be part of a ConSource module. Fig.44A is a schematic diagram depicting an example embodiment in which the LCD 114, the converter V1 or V2 206, 308, and the energy buffer 204 are each mounted or secured to a single common substrate 4402, which may be a single printed circuit board (PCB). These components may be electrically coupled to the substrate 4402 and to each other to permit signal or data exchange therebetween. Other passive or active components may also be mounted or secured to the substrate 4402.

[0273] Fig.44Bis a schematic view depicting an example embodiment in which converters V1 or V2 206, 308 and energy buffer 204 are each mounted or secured to a single common substrate 4404, which may be a single printed circuit board (PCB). These components may be electrically coupled to substrate 4404 and to each other to permit signal or data exchange therebetween. LCD 114 is mounted or secured to a different substrate 4406, which may also be a single PCB. Other passive or active components may be mounted or secured to substrates 4404 and 4406 alike. Communication between components on the LCD and substrate 4404 may be via one or more buses, wires, or optical fibers.

[0274] In the embodiments described herein, intra-phase balancing can be achieved by one or more intra-phase balancing controllers, and inter-phase balancing can be achieved by one or more inter-phase balancing controllers. These intra-phase balancing controllers and inter-phase balancing controllers can be implemented in hardware, software, or a combination thereof. These intra-phase balancing controllers and inter-phase balancing controllers can be implemented entirely by a device such as a master control device. These intra-phase balancing controllers and inter-phase balancing controllers can be implemented in a distributed manner between multiple devices such as a master control device and one or more local control devices.

[0275] System 100 can operate across a wide frequency range as may be required in various fixed and mobile applications. For example, the system AC output frequency in a fixed application will typically be 60 Hz. In an embodiment where each switch in circuit 207 uses a MOSFET ( Figure 5A ), the switching frequency (Fsw) of each MSOFET can be in the range of 1Khz-2kHz or higher. In the example with 8 modules in each phase array, the resulting pulsation frequency of the AC output voltage will be 2Fsw*N = 16kHz-32kHz or higher. The switching frequency of conventional systems (such as IGBT-based high power inverters) is typically less than 5kHz. In mobile applications, the system frequency will depend on the needs of the (one or more) motors, which for sinusoidal output waveforms typically range from 0Hz to 2000Hz or higher. In the example embodiment where the Fsw of the switch of circuit 207 is 5Khz, then the switching frequency (equivalent output pulsation) of the example system 100 with five series modules will be 2*5kHz*5=50kHz. This is compared to conventional power inverters with switching frequencies of less than 20kHz. These examples merely illustrate the enhanced performance of system 100 over conventional systems and are by no means intended to be limiting.

[0276] In all embodiments described herein, the primary energy source of each module of a particular system can have the same voltage (either a standard operating voltage or a nominal voltage). Such a configuration simplifies the management and construction of the system. The primary and secondary energy sources can also have the same voltage (standard or nominal). Other configurations can be implemented, such as configurations in which the primary energy sources of different modules of the same system have different voltages (standard or nominal), and configurations in which the primary and secondary energy sources of the modules have different voltages (standard or nominal). Still other configurations can be implemented in which the primary energy sources of system modules have primary energy source batteries that are different chemical compositions, or system modules have primary energy source batteries of a first chemical composition and secondary energy source batteries of a second chemical composition. Modules that are different from each other can be based on placement in the system (e.g., modules within a phase array are different from (one or more) IC modules).

[0277] exist Figures 1A-8F , 11, 13, 15-30, 32, 41A-41F and 43A-44B, various components (e.g., elements, components, devices, systems and / or functional blocks) of each figure are depicted as being coupled or connected to one or more other components (e.g., elements, components, devices, systems and / or functional blocks) with one or more other components (e.g., elements, components, devices, systems and / or functional blocks). These components are generally shown as being coupled or connected without the presence of an intermediate entity, such as in a direct coupling or connection. In view of this specification, a person of ordinary skill in the art will readily recognize that these couplings or connections can be direct (without one or more intermediate components) or indirect (with one or more intermediate components not shown). Therefore, this paragraph serves as a prior support for all couplings or connections that are directly coupled or indirectly coupled or connected.

[0278] A detailed discussion of systems (e.g., ACi battery packs), devices, and methods that may be used in conjunction with the systems, devices, and methods described herein is provided in International Publication No. WO 2019 / 183553, filed on March 22, 2019, and entitled “Systems And Methods For Power Management And Control,” which is incorporated herein by reference for all purposes as if fully set forth.

[0279] When used as a battery pack in, for example, the automotive industry, the embodiments described herein permit the elimination of a conventional battery management system as a subsystem accompanying each battery module. The functionality typically performed by a battery management system is subsumed or replaced by the different and in many ways greater functionality of the system embodiments described herein.

[0280] Those of ordinary skill in the art will appreciate that the term "module" as used herein refers to a device, assembly, or subsystem within the system 100, and that the system 100 need not be configured to permit each individual module to be physically removable and replaceable relative to the other modules. For example, the system 100 may be packaged in a common housing that does not permit removal and replacement of any one module without requiring the system to be disassembled as a whole. However, any and all embodiments herein may be configured such that each module is removable and replaceable relative to the other modules in a convenient manner, such as without requiring disassembly of the system.

[0281] The term "master control device" as used herein is broad and does not require implementation of any specific protocol, such as a master and slave relationship with any other device (such as a local control device).

[0282] The term "output" as used herein is broad and does not exclude functioning in a bidirectional manner as both output and input. Similarly, the term "input" as used herein is broad and does not exclude functioning in a bidirectional manner as both output and input.

[0283] The terms "terminal" and "port" as used herein are broad and may be unidirectional or bidirectional, input or output, and do not require a specific physical or mechanical structure such as a female or male configuration.

[0284] The example embodiments described herein may be used with one or more cooling systems to dissipate heat from any and all components of the system (e.g., switching circuits, energy sources, energy buffers, control circuits, etc.). The cooling system may utilize a cooling medium such as a gas, liquid, or solid. The cooling system may utilize one or more piezoelectric cooling elements.

[0285] The various aspects of the subject matter are set forth below to review and / or supplement the embodiments described so far, with emphasis on the interrelationship and interchangeability of the following embodiments. In other words, emphasis is placed on the fact that each feature of an embodiment can be combined with each and every other feature, unless otherwise expressly stated or logically implausible.

[0286] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source, an energy buffer coupled to the first energy source, and a converter coupled to the first energy source and the energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module. In these embodiments, the module-based energy system further includes a local control device communicatively coupled to the converter-source module, wherein the local control device is configured to generate a plurality of switching signals for the plurality of switches.

[0287] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source, an energy buffer coupled to the first energy source, and a converter coupled to the first energy source and the energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module. In these embodiments, the module-based energy system further includes a local control device communicatively coupled to the converter-source module, wherein the first energy source provides operating power to the local control device.

[0288] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source, an energy buffer coupled to the first energy source, and a converter coupled to the first energy source and the energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module. In these embodiments, the module-based energy system further includes a local control device communicatively coupled to the converter-source module, wherein the local control device is configured to detect a fault in the converter-source module and generate a fault signal. In these embodiments, the fault signal indicates an actual fault or a potential fault. In many of these embodiments, the module-based energy system further includes a master control device communicatively coupled to the local control device, wherein the local control device is configured to output a fault signal to the master control device.

[0289] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source, an energy buffer coupled to the first energy source, and a converter coupled to the first energy source and the energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module. In these embodiments, the module-based energy system further includes a local control device communicatively coupled to the converter-source module, wherein the local control device, the energy buffer, and the converter are implemented together on a single printed circuit board.

[0290] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source, an energy buffer coupled to the first energy source, and a converter coupled to the first energy source and the energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module. In these embodiments, the module-based energy system further includes a local control device communicatively coupled to the converter-source module, wherein the local control device, the energy buffer, and the converter are housed in a common housing that does not house the first energy source.

[0291] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source, an energy buffer coupled to the first energy source, and a converter coupled to the first energy source and the energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module. In these embodiments, the module-based energy system further includes a local control device communicatively coupled to the converter-source module, wherein the local control device, the first energy source, the energy buffer, and the converter are housed in a common housing that does not house another converter-source module.

[0292] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source, an energy buffer coupled to the first energy source, and a converter coupled to the first energy source and the energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module. In these embodiments, the module-based energy system further includes a local control device communicatively coupled to the converter-source module, wherein the local control device, the energy buffer, and the converter are housed in a common housing that does not house the first energy source.

[0293] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source, an energy buffer coupled to the first energy source, and a converter coupled to the first energy source and the energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module, and wherein the energy buffer and the converter are implemented together on a single printed circuit board.

[0294] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source including a fuel cell unit, an energy buffer coupled to the first energy source, and a converter coupled to the first energy source and the energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module.

[0295] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source, an energy buffer coupled to the first energy source, and a converter coupled to the first energy source and the energy buffer, wherein the energy buffer includes a Z-source network including two inductors and two capacitors, or a quasi-Z-source network including two inductors, two capacitors and a diode. In these embodiments, the converter-source module further includes a converter coupled to the first energy source and the energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module.

[0296] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source, an energy buffer coupled to the first energy source, a second energy source, and a converter including a first input, a second input, and a third input, wherein the first and third inputs are coupled to the first energy source and the energy buffer, wherein the second and third inputs are coupled to the second energy source, wherein the converter further includes a plurality of switches configured to select an output voltage of the module, and wherein both the first and second energy sources include a battery or neither of the first and second energy sources includes a battery.

[0297] In many of these embodiments, the first and second energy sources each include a capacitor or a fuel cell unit. In many of these embodiments, the converter includes a first switch, an inductor, and a second switch, wherein the first switch is coupled between the first input and the first node, the inductor is coupled between the second input and the first node, and the second switch is coupled between the third input and the first node. In many of these embodiments, the plurality of switches includes a third switch, a fourth switch, a fifth switch, and a sixth switch. In many of these embodiments, both the first and second energy sources include a battery, wherein the second energy source further includes a first capacitor connected in parallel with the battery. In many of these embodiments, both the first and second energy sources include a battery, wherein the second energy source further includes a first capacitor connected in parallel with the battery and a second capacitor connected in parallel with the battery.

[0298] In many embodiments, a module-based energy system includes a converter-source module. In these embodiments, the converter-source module includes a first energy source, an energy buffer coupled to the first energy source, and a converter coupled to the first energy source and the energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module. In these embodiments, the converter-source module further includes a first output port for connecting to a primary load or another converter-source module and a second output port for connecting to an auxiliary load.

[0299] In many of these embodiments, the auxiliary load is a first auxiliary load, and the converter-source module includes a third output port for connecting to a second auxiliary load. In many of these embodiments, the first output port is coupled to the main load or another converter-source module, the second output port is coupled to the first auxiliary load, and the third output port is coupled to the second auxiliary load. In many of these embodiments, the converter includes a first input, a second input, and a third input, wherein the first and third inputs are coupled to a first energy source, an energy buffer, and a second output port, and wherein the second and third inputs are coupled to the third output port. In many of these embodiments, the converter includes a first switch, an inductor, and a second switch, wherein the first switch is coupled between the first input and the first node, the inductor is coupled between the second input and the first node, and the second switch is coupled between the third input and the first node. In many of these embodiments, the plurality of switches includes a third switch, a fourth switch, a fifth switch, and a sixth switch. In many of these embodiments, the third switch, the fourth switch, the fifth switch, and the sixth switch are coupled together as an H-bridge. In many of these embodiments, the first output port includes a first output and a second output, wherein the third switch is coupled between the first input and the first output, the fourth switch is coupled between the third input and the first output, the fifth switch is coupled between the first input and the second output, and the sixth switch is coupled between the third input and the second output.

[0300] In many of the aforementioned embodiments, the module-based energy system further includes a plurality of converter-source modules coupled to the converter-source module in an array.

[0301] In many of these embodiments, each converter-source module in the plurality of converter-source modules includes a first energy source, an energy buffer coupled to the first energy source, and a converter, the converter including a plurality of switches configured to select an output voltage of the converter-source module. In many of these embodiments, the plurality of switches select between a first voltage having a positive polarity, a zero voltage or a reference voltage, and a first voltage having a negative polarity. In many of these embodiments, the first voltage is a direct current (DC) voltage. In many of these embodiments, the array is configured to output an alternating current (AC) signal.

[0302] In many of the aforementioned embodiments, the converter includes one or more sensors configured to output one or more sensing signals indicating a temperature of the first energy source, a charge state of the first energy source, a voltage or a current of the first energy source.

[0303] In many of the aforementioned embodiments, the module-based energy system further includes a local control device communicatively coupled to the converter-source module.

[0304] In many of these embodiments, the module-based energy system further comprises a plurality of converter-source modules and a plurality of local control devices, wherein each of the plurality of local control devices is dedicated for use with one of the plurality of converter-source modules. In many of these embodiments, the converter-source module is a first converter-source module, wherein the system comprises a second converter-source module, and wherein the local control device controls both the first and second converter-source modules.

[0305] In many of the aforementioned embodiments, the local control device includes a processing circuit and a memory communicatively coupled to the processing circuit, wherein the memory includes instructions executable by the processing circuit.

[0306] In many of the aforementioned embodiments, the local control device is configured to generate the switching signals for the converter using pulse width modulation.

[0307] In many of these embodiments, the local control device is configured to modulate or scale the received reference signal and use the modulated reference signal for generation of the switch signal. In many of these embodiments, the local control device is configured to modulate the received reference signal using a received modulation index.

[0308] In many of the aforementioned embodiments, the local control device is configured to receive one or more signals indicative of one or more of the following operating characteristics of the converter-source module or components thereof: temperature, state of charge, capacity, state of health, voltage, or current.

[0309] In many of these embodiments, the local control device is configured to transmit to the master control device information indicative of one or more of the following operating characteristics of the converter-source module or components thereof: temperature, state of charge, capacity, state of health, voltage, or current.

[0310] In many of the aforementioned embodiments, the local control device is powered only by the first energy source.

[0311] In many of the aforementioned embodiments, the local control device is powered by an energy source other than the first energy source.

[0312] In many of the aforementioned embodiments, the converter-source module includes a second energy source, wherein the local control device is configured to cause the converter-source module to actively filter a second harmonic in an output current from the first energy source with current from the second energy source.

[0313] In many of these embodiments, the first energy source comprises a battery and the second energy source comprises a capacitor. In many of these embodiments, the capacitor of the second energy source is a supercapacitor or ultracapacitor.

[0314] In many of the aforementioned embodiments, the converter-source module includes a second energy source, wherein the local control device is configured to control the converter to manage power transfer: from the first energy source to the cumulative load of the converter-source module, from the second energy source to the cumulative load of the converter-source module, and between the first energy source and the second energy source.

[0315] In many of these embodiments, the power transfer between the first energy source and the second energy source includes power transfer from the first energy source to the second energy source and power transfer from the second energy source to the first energy source. In many of these embodiments, the local control device is configured to control the converter to manage power transfer based at least in part on the power consumption of the first auxiliary load and the power consumption of the second auxiliary load. In many of these embodiments, the local control device includes a processor and a memory, wherein the memory includes instructions that, when executed by the processing circuit, cause the processing circuit to manage power transfer: from the first energy source to the cumulative load of the converter-source module, from the second energy source to the cumulative load of the converter-source module, and between the first energy source and the second energy source. In many of these embodiments, the local control device is configured to manage power transfer by generating a switching signal for the converter.

[0316] In many of the aforementioned embodiments, the module-based energy system further includes a master control device configured to manage one or more operating parameters of the converter-source module relative to one or more operating parameters of other converter-source modules within the system.

[0317] In many of the aforementioned embodiments, the module-based energy system further includes a master control device communicatively coupled to the local control device.

[0318] In many of these embodiments, the master control device is communicatively coupled to the local control device via a serial data cable. In many of these embodiments, the master control device includes a processing circuit and a memory communicatively coupled to the processing circuit, wherein the memory includes instructions executable by the processing circuit. In many of these embodiments, the module-based energy system further includes a plurality of local control devices coupled to a plurality of converter-source modules, wherein the master control device is communicatively coupled to each of the plurality of local control devices. In many of these embodiments, the master control device is configured to read data indicating one or more operating characteristics of the plurality of converter-source modules and determine the contribution of at least one converter-source module in the plurality of converter-source modules. In many of these embodiments, the master control device is configured to determine the contribution of each of the plurality of converter-source modules. In many of these embodiments, the master control device is configured to output a modulation or scaling index of each of the plurality of converter-source modules, wherein the modulation or scaling index indicates a power flow contribution. In many of these embodiments, the master control device is configured to output a reference signal to each local control device, wherein each local control device is configured to modulate or scale the reference signal using a received modulation or scaling index and to generate a switching signal based on the modulated or scaled reference signal.

[0319] In many of the aforementioned embodiments, the module-based energy system is configured for operation in a mobile entity.

[0320] In many of these embodiments, the mobile entity is one of: a car, a bus, a truck, a motorcycle, a scooter, an industrial vehicle, a mining vehicle, an aircraft, a marine vessel, a locomotive, a train or a rail-based vehicle or a military vehicle.

[0321] In many of the aforementioned embodiments, the module-based energy system is configured to operate as a stationary energy system.

[0322] In many of these embodiments, the stationary energy system is one of: a residential storage system, an industrial storage system, a commercial storage system, a data center storage system, a power grid, a microgrid, or a charging station.

[0323] In many of the aforementioned embodiments, the module-based energy system is configured as a battery pack for an electric vehicle.

[0324] In many embodiments, a module-based energy system includes a plurality of converter-source modules, each converter-source module including a first energy source, an energy buffer, and a converter electrically coupled together, wherein the plurality of converter-source modules are electrically coupled together in an array. In these embodiments, the module-based energy system further includes a control circuit communicatively coupled to the plurality of converter-source modules, wherein the control circuit is configured to monitor at least one operating characteristic of each of the plurality of converter-source modules, and based on the monitored at least one operating characteristic, independently control each converter-source module within the plurality of converter-source modules to optimize the performance of the array.

[0325] In many of these embodiments, at least one operating characteristic is selected from: state of charge, temperature, state of health, capacity, fault presence, voltage or current. In many of these embodiments, temperature is at least one of the following: temperature of the first energy source or a component thereof, temperature of the energy buffer or a component thereof, temperature of the converter or a component thereof. In many of these embodiments, capacity is at least one of the following: capacity of the first energy source or capacity of one or more components of the first energy source. In many of these embodiments, fault presence is at least one of the following: an indication of the presence of a measured fault, an indication of the presence of a potential fault; an indication of the presence of an alarm condition, or an indication of the presence of a warning condition. In many of these embodiments, voltage is at least one of the following: voltage of the first energy source or a component thereof, voltage of the energy buffer or a component thereof, voltage of the converter or a component thereof. In many of these embodiments, current is at least one of the following: current of the first energy source or a component thereof, current of the energy buffer or a component thereof, current of the converter or a component thereof. In many of these embodiments, each converter-source module includes at least one sensor to sense at least one operating characteristic. In many of these embodiments, the control circuit is configured to monitor all of the following operating characteristics: state of charge, temperature, state of health, capacity, fault presence, voltage, and current. In many of these embodiments, the control circuit is configured to independently control the discharge or charge of each converter-source module by generating and outputting a plurality of switching signals to the converter of each converter-source module. In many of these embodiments, the control circuit is configured to generate the plurality of switching signals using pulse width modulation or hysteresis.

[0326] In many of these embodiments, at least one converter-source module of the plurality of converter-source modules is a converter-source module as described in many of the aforementioned embodiments.

[0327] In many of these embodiments, each converter-source module of the plurality of converter-source modules is a converter-source module as described in many of the aforementioned embodiments.

[0328] In many of these embodiments, the control circuit is configured to independently control the discharge or charge of each converter-source module within the plurality of converter-source modules for performance optimization of the array. In many of these embodiments, the control circuit is configured to independently control the discharge or charge of each converter-source module based on the power requirements of a load coupled to the array. In many of these embodiments, the load is a motor, a commercial structure, a residential structure, an industrial structure, or an energy grid. In many of these embodiments, the control circuit includes a plurality of local control devices and a master control device communicatively coupled to the plurality of local control devices.

[0329] In many embodiments, a module-based energy system comprises an array of N converter-source modules, wherein N is 2 or greater, wherein each of the N converter-source modules is connected in series, wherein each of the N converter-source modules is configured according to any one of the aforementioned embodiments, and wherein the array comprises a first output terminal of a first converter-source module and a second output terminal of an Nth converter-source module.

[0330] In many of these embodiments, the module-based energy system further includes a plurality of local control devices, each of which is communicatively coupled to one or more of the N converter-source modules. In many of these embodiments, the module-based energy system further includes a master controller communicatively coupled to the plurality of local control devices. In many of these embodiments, the module-based energy system further includes a load connected between the first and second output terminals. In many of these systems, the load is one of a DC load or a single-phase AC load.

[0331] In many embodiments, the module-based energy system includes M arrays of converter-source modules, where M is 2 or greater, where each of the M arrays includes N converter-source modules, where N is 2 or greater, where each of the N converter-source modules is connected in series in each of the M arrays, where each of the N converter-source modules is configured according to any of the aforementioned embodiments, where each of the M arrays includes individual output terminals of a first converter-source module, and where the Nth converter-source module of each of the M arrays is connected to a common output terminal.

[0332] In many of these embodiments, the module-based energy system further includes a plurality of local control devices, each of which is communicatively coupled to one or more of the N converter-source modules of each of the M arrays. In many of these embodiments, the module-based energy system further includes a master controller communicatively coupled to the plurality of local control devices. In many of these embodiments, the M arrays include a first and a second array. In many of these embodiments, the module-based energy system further includes a load connected between the individual output terminals of the first and second arrays. In many of these embodiments, the common output terminal is coupled to the neutral point of the load. In many of these embodiments, the module-based energy system further includes a load connected between the common output terminal and the joint coupling of the individual output terminals of the first and second arrays. In many of these embodiments, the load is one of a DC load or a single-phase AC load. In many of these embodiments, the M arrays include a first, a second, and a third array. In many of these embodiments, the module-based energy system further includes a three-phase load connected between the individual output terminals of the first, second, and third arrays. In many of these embodiments, the common output terminal is coupled to the neutral point of the load. In many of these embodiments, the module-based energy system further includes a DC or single-phase AC load connected between the common output terminal and a joint coupling of the individual output terminals of the first, second, and third arrays.

[0333] In many of these embodiments, the module-based energy system further comprises a plurality of local control devices, each local control device being communicatively coupled to one or more of the N converter-source modules of the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, and twelfth arrays. In many of these embodiments, the module-based energy system further comprises a master controller communicatively coupled to the plurality of local control devices.

[0334] In many embodiments, a module-based energy system includes a plurality of connected converter-source modules and control circuitry, wherein the control circuitry is configured to adjust contributions of one or more converter-source modules based on status information associated with the one or more converter-source modules.

[0335] In many of these embodiments, the converter-source module comprises a converter-source module according to many of the aforementioned embodiments.

[0336] In many of these embodiments, the converter-source module includes an energy source including at least one energy storage element, an energy buffer, and a converter. In many of these embodiments, the state information includes one or more of the state of charge, health state, temperature, capacity, current, or voltage of the converter-source module or its components. In many of these embodiments, the master control device is configured to balance the state of charge (SOC) of multiple connected converter-source modules. In many of these embodiments, the control circuit includes a processing circuit and at least one memory having instructions stored thereon, which, when executed by the processing circuit, causes the processing circuit to cause an adjustment of the contribution of one or more converter-source modules based on the state information associated with one or more converter-source modules. In many of these embodiments, the processing circuit and at least one memory are components of the master control device, the local control device, or are distributed between the master control device and one or more local control devices.

[0337] In many of these embodiments, the control circuit is configured to reduce the contribution of the first converter-source module relative to the one or more other converter-source modules based on the status information of the first converter-source module and the one or more other converter-source modules. In many of these embodiments, the status information of the first converter-source module indicates at least one of the following: a relatively lower state of charge, a relatively lower state of health, a relatively lower capacity, a relatively lower voltage, a relatively lower current, a relatively higher temperature, or a fault, compared to the status information of the one or more other converter-source modules.

[0338] In many of these embodiments, the control circuit is configured to increase the contribution of the first converter-source module relative to the one or more other converter-source modules based on the status information of the first converter-source module and the one or more other converter-source modules. In many of these embodiments, the status information of the first converter-source module indicates at least one of the following: a relatively higher state of charge, a relatively higher state of health, a relatively higher capacity, a relatively higher voltage, a relatively higher current, a relatively lower temperature, or the absence of a fault, compared to the status information of the one or more other converter-source modules.

[0339] In many of these embodiments, the contribution is an output power of the first converter-source module over time. In many of these embodiments, the control circuit includes a master control device and a plurality of local control devices. In many of these embodiments, the master control device is configured to generate a plurality of modulation indices for the plurality of converter-source modules, wherein a modulation index is independently generated for each converter-source module in the plurality of converter-source modules.

[0340] In many of these embodiments, the main control device includes an intra-phase balancing controller. In many of these embodiments, the intra-phase balancing controller is configured to generate a modulation index for each converter-source module. In many of these embodiments, the modulation index of the converter-source module is determined based on one or more of the following: a peak voltage Vpk of a reference voltage Vr of an energy system based on the module, a charge state of the converter-source module, a temperature of the converter-source module, a capacity of the converter-source module, a current of the converter-source module, or a voltage of the converter-source module. In many of these embodiments, the main control device further includes a peak detector for detecting a peak voltage Vpk of a reference voltage Vr of an energy system based on the module. In many of these embodiments, the main control device is configured to generate a normalized reference waveform Vrn from a reference voltage Vr. In many of these embodiments, the main control device is configured to generate a normalized reference waveform Vrn from a reference voltage Vr by dividing the reference voltage Vr by its peak voltage Vpk. In many of these embodiments, the main control device is configured to output a normalized reference waveform Vrn to each of a plurality of local control devices. In many of these embodiments, each of the plurality of local control devices is configured to modulate the received normalized reference waveform Vrn by the received modulation index. In many of these embodiments, each of the plurality of local control devices is configured to generate a switching signal for the converter-source module based on the modulated reference waveform. In many of these embodiments, each of the plurality of local control devices is configured to generate a switching signal for the converter-source module based on a pulse width modulation technique implemented with the modulated reference waveform.

[0341] In many of these embodiments, multiple modulation indices are generated to ensure that the sum of the generated voltages from multiple converter-source modules does not exceed the peak voltage Vpk. In many of these embodiments, multiple modulation indices Mi are generated to converge the state of charge (SOC) of the energy sources of multiple converter-source modules toward a balanced condition. In many of these embodiments, multiple modulation indices Mi are generated to converge the state of health (SOH) of multiple converter-source modules toward a balanced condition. In many of these embodiments, multiple modulation indices Mi are generated to converge the capacity of multiple converter-source modules toward a balanced condition. In many of these embodiments, multiple modulation indices Mi are generated to converge the voltage of multiple converter-source modules toward a balanced condition. In many of these embodiments, multiple modulation indices Mi are generated to converge the current of multiple converter-source modules toward a balanced condition. In many of these embodiments, multiple modulation indices Mi are generated to converge the temperature of multiple converter-source modules toward a balanced condition. In many of these embodiments, multiple modulation indices Mi are generated to reduce the contribution of one or more converter-source modules with a fault condition compared to one or more other converter-source modules without a fault condition.

[0342] In many of these embodiments, the control circuit includes one or both of an interphase balance controller or an intraphase balance controller. In many of these embodiments, a plurality of converter-source modules are arranged in a multi-dimensional array. In many of these embodiments, the intra-phase balance controller is configured to adjust the contribution of a plurality of converter-source modules within a one-dimensional array of the multi-dimensional array. In many of these embodiments, the interphase balance controller is configured to control one or more of a neutral point offset or a contribution of a converter-source module common to each phase.

[0343] In many of the aforementioned embodiments, the module-based energy system is one of single-phase or multi-phase. In many of these embodiments, the module-based energy system is a multi-phase module-based energy system that outputs a three-phase, four-phase, five-phase or six-phase signal.

[0344] In many of the aforementioned embodiments, a plurality of converter-source modules are arranged in a multi-dimensional array.

[0345] In many of the aforementioned embodiments, a plurality of converter-source modules are arranged according to any of the many of the aforementioned embodiments.

[0346] In many of the aforementioned embodiments, the module-based energy system is configured for operation in an electric or hybrid mobile vehicle. In many of these embodiments, the electric or hybrid mobile vehicle is one of: a car, a bus, a truck, a motorcycle, a scooter, an industrial vehicle, a mining vehicle, an aircraft, a marine vessel, a locomotive, or a rail-based vehicle or a military vehicle.

[0347] In many of the aforementioned embodiments, the module-based energy system is configured to operate as a stationary energy system. In many of these embodiments, the stationary energy system is one of the following: a residential system, an industrial system, a commercial system, a data center storage system, a power grid, a microgrid, or a charging station.

[0348] In many of the aforementioned embodiments, the module-based energy system is configured as a battery pack for an electric vehicle.

[0349] In many embodiments, a module-based energy system comprises a plurality of connected converter-source modules and a control circuit, wherein the control circuit is configured to adjust power supply to one or more converter-source modules based on status information associated with the one or more converter-source modules. In many of these embodiments, each converter-source module comprises a converter-source module according to many of the aforementioned embodiments.

[0350] In many of these embodiments, each converter-source module includes an energy source including at least one energy storage element, an energy buffer, and a converter. In many of these embodiments, the control circuit is configured to independently determine the amount of charge received by each converter-source module of the system from a power source external to the system. In many of these embodiments, the control circuit is configured to independently determine the amount of charge received by each converter-source module of the system from a power source external to the system based on state information associated with one or more converter-source modules or components thereof, wherein the state information includes one or more of the following: state of charge (SOC), state of health (SOH), capacity, temperature, voltage, current, presence of a fault, or absence of a fault. In many of these embodiments, multiple converter-source modules are arranged in a multi-dimensional array. In many of these embodiments, multiple converter-source modules are arranged according to many of the aforementioned embodiments.

[0351] In many embodiments, a converter-source module includes an energy source including at least one energy storage element, an energy buffer, and a plurality of converters configured to generate an output voltage based on a combination of a plurality of switches.

[0352] In many of these embodiments, the output of the energy source may be coupled to the input terminal of the energy buffer. In many of these embodiments, the output of the energy buffer may be coupled to the input terminal of the converter. In many of these embodiments, the energy storage element is a supercapacitor, a battery including at least one battery cell or a plurality of battery cells connected in series and / or in parallel, or one of the fuel cell cells. In many of these embodiments, the energy buffer includes one or more of the following: an electrolytic capacitor, a film capacitor, a Z source network including two inductors and two capacitors, or a quasi-Z source network including two inductors, two capacitors and a diode. In many of these embodiments, each of the multiple switches includes at least one of a semiconductor MOSFET or a semiconductor IGBT. In many of these embodiments, the converter is configured to generate three different voltage outputs by different combinations of multiple switches. In many of these embodiments, the energy source is configured to output a DC voltage VDC, and the three different voltage outputs are +VDC, 0 and –VDC. In many of these embodiments, the converter-source module is configured to receive switching signals of multiple switches from a local control device.

[0353] In many embodiments, according to many of the aforementioned embodiments, the energy system comprises at least two converter-source modules.

[0354] In many of these embodiments, at least two converter-source modules are connected in one of a one-dimensional array or a multi-dimensional array. In many of these embodiments, at least two one-dimensional arrays are connected together at different rows and columns directly or via additional converter-source modules. In many of these embodiments, the energy system includes at least two local control devices, one for each converter-source module. In many of these embodiments, each local control device manages energy from an energy source, protects an energy buffer, and controls a converter.

[0355] In many embodiments, a module-based energy system includes a local control device and a converter-source module connected to the local control device, wherein the converter-source module includes an energy source having a storage element, first and second outputs of the energy source are connected to first and second inputs of an energy buffer, the first and second outputs of the energy buffer are connected to first and second inputs of a converter, the converter includes at least four switches to generate three voltage levels, the three voltage levels include a first voltage level with a positive polarity, a zero voltage level or a reference voltage level, and a first voltage level with a negative polarity, wherein the three voltage levels are generated by connecting the first voltage level between the first and second inputs of the converter to the first and second outputs of the converter through different combinations of the at least four switches.

[0356] In many of these embodiments, the storage element comprises a supercapacitor, a battery module comprising one or more connected battery cells, and a fuel cell unit module. In many of these embodiments, the energy buffer comprises an electrolytic and / or film capacitor, a Z source network formed by two inductors and two electrolytic and / or film capacitors, and a quasi-Z source network formed by two inductors, two electrolytic and / or film capacitors and a diode. In many of these embodiments, the switch is configured as a semiconductor switch. In many of these embodiments, the energy source comprises a primary energy source and a secondary energy source, wherein the primary energy source comprises a storage element, which comprises a supercapacitor, a battery module comprising one or more connected battery cells, and a fuel cell unit module. In many of these embodiments, the first and second outputs of the primary energy source are coupled to the first and second input terminals of the energy buffer, wherein the energy buffer comprises an electrolytic and / or film capacitor, a Z source network formed by two inductors and two electrolytic and / or film capacitors, and a quasi-Z source network formed by two inductors, two electrolytic and / or film capacitors and a diode. In many of these embodiments, the second output of the energy buffer is connected to the second output of the secondary energy source, and wherein the first output of the secondary energy source is connected to the second input of the converter. In many of these embodiments, the secondary energy source includes a storage element, which includes one of the following: an electrolytic and / or film capacitor, a supercapacitor, a battery module including one or more connected battery cells, an electrolytic and / or film capacitor connected in parallel with a supercapacitor, an electrolytic and / or film capacitor connected in parallel with a battery module including one or more connected battery cells, an electrolytic and / or film capacitor connected in parallel with a supercapacitor, and a battery module including one or more connected battery cells. In many of these embodiments, the converter includes six switches. In many of these embodiments, the converter-source module is configured to power the first and second auxiliary loads.

[0357] In many of these embodiments, the system further includes a balancing controller. In many of these embodiments, the balancing controller is a single-phase balancing controller. In many of these embodiments, the balancing controller includes a peak detector, a frequency divider, and an intra-phase balancing controller. In many of these embodiments, the system further includes a plurality of converter-source modules, and the balancing controller is configured to balance the charge state and temperature between the plurality of converter-source modules of the system. In many of these embodiments, the balancing controller is a three-phase balancing controller. In many of these embodiments, the balancing controller includes an inter-phase balancing controller and a plurality of intra-phase controllers. In many of these embodiments, the system further includes a plurality of converter-source modules, and the balancing controller is configured to balance the charge state and temperature between the plurality of converter-source modules of the system.

[0358] In many embodiments, a module-based energy system is provided, comprising a converter-source module, the converter-source module comprising: a first energy source; and a converter coupled to the first energy source, wherein the converter comprises a plurality of switches configured to select an output voltage of the module.

[0359] In many embodiments, a method for supplying output power from a module-based energy system is provided, the method comprising: receiving, by a control circuit of the system, status information from at least one of a plurality of converter-source modules of the system, wherein each converter-source module comprises an energy source and a converter, and wherein each converter-source module is configured to contribute power to the output power of the system; and controlling, by the control circuit, the power contribution of at least one converter-source module of the plurality of converter-source modules based on the status information.

[0360] In these embodiments, the control circuit may include a master control device and a plurality of local control devices. The master control device may receive status information from at least one local control device, and the method may further include outputting a reference waveform and a modulation index from the master control device to at least one local control device. The method may further include: modulating the reference waveform with the modulation index by the local control device; and generating a plurality of switching signals for converters of a converter-source module associated with the local control device based at least in part on the modulated reference waveform. The switching signals may be generated using pulse width modulation.

[0361] In these embodiments, controlling the power contribution of at least one converter-source module by the control circuit may include: generating a plurality of switching signals from the control circuit and outputting them to a converter of the at least one converter-source module, wherein the method further includes switching, by the converter, an output voltage of the at least one converter-source module.

[0362] In these embodiments, controlling the power contribution of at least one converter-source module by the control circuit may include reducing the power contribution of at least one converter-source module or increasing the power contribution of at least one converter-source module. The power contribution may be reduced or increased compared to a previous power contribution of the at least one converter-source module or compared to power contributions of one or more other converter-source modules.

[0363] In these embodiments, the control circuit may control the power contribution of each converter-source module in the plurality of converter-source modules.

[0364] In these embodiments, the control circuit may control the power contribution based on pulse width modulation or hysteresis techniques.

[0365] In these embodiments, the control circuitry may repeatedly receive status information for each converter-source module, wherein the status information is specific to each individual converter-source module. The control circuitry may control each converter-source module based on the status information, wherein the control occurs in real time.

[0366] In many embodiments, a method for charging a module-based energy system is provided, the method comprising: receiving, by a control circuit of the system, status information from at least one of a plurality of converter-source modules of the system, wherein each converter-source module comprises an energy source and a converter, and wherein each converter-source module is configured to be charged by a power source; and controlling, by the control circuit, power consumption of at least one converter-source module of the plurality of converter-source modules based on the status information.

[0367] In these embodiments, controlling the power consumption of at least one converter-source module by the control circuit may include: generating a plurality of switching signals from the control circuit and outputting them to a converter of the at least one converter-source module, and wherein the method may further include switching a plurality of switches by the converter such that the power consumption of the at least one converter-source module is reduced or increased, optionally wherein the power consumption is reduced or increased compared to a previous power consumption of the at least one converter-source module, or compared to a power consumption of one or more other converter-source modules.

[0368] In many embodiments, a module-based energy system is provided, the system comprising: a first array of cascaded modules configured to output a first voltage waveform to a load; a second array of cascaded modules configured to output a second voltage waveform to the load, wherein the first and second voltage waveforms each have a different phase angle; and an interconnection module coupled to both the first array and the second array, wherein the interconnection module comprises an energy source and a switching circuit, and wherein the interconnection module is configured to adjust the amount of energy supplied by the energy source to the first and / or second arrays.

[0369] In many embodiments, the first array and the second array are electrically positioned between the load and the interconnect module.

[0370] In some embodiments, the system further includes a control circuit configured to control a switch circuit, wherein the energy source has a positive node and a negative node, and wherein the switch circuit of the interconnect module is controllable to selectively couple the first and / or second arrays to the first and / or second nodes of the energy source. The control circuit can be configured to control the switch circuit so that under an unbalanced condition between the first array and the second array, the energy source releases relatively more energy to the first array than to the second array. The unbalanced condition can be related to a charge state, a temperature, a capacity, a health state, a voltage and / or a current. The control circuit can be configured to control the switch circuit so that the energy source releases relatively more energy to the first array for supply to the load from the first array.

[0371] In some embodiments, the unbalanced condition is that the first array has a relatively lower overall energy level than the second array.

[0372] In some embodiments, the control circuit is configured to receive charge state information from each cascaded module of the first array and the second array, determine whether the first array or the second array has a relatively lower overall charge state, and cause the energy sources of the interconnected modules to release more energy to the one of the first array and the second array having a relatively lower charge state.

[0373] In some embodiments, the unbalanced condition is that the first array has a relatively higher temperature than the second array.

[0374] In some embodiments, the control circuit is configured to receive temperature information from each cascade module of the first array and the second array, determine whether the first array or the second array has a relatively higher temperature, and cause the energy source of the interconnected modules to release more energy to the one of the first array and the second array having a relatively higher temperature.

[0375] In some embodiments, the control circuit is configured to control the balance of inter-phase energy between the first array and the second array using the energy source of the interconnected module.

[0376] In some embodiments, the control circuit is configured to control the balance of inter-phase energy between the first array and the second array using a shift toward a neutral point of the first array and the second array.

[0377] In some embodiments, the control circuit is configured to control the switching circuit according to a pulse width modulation or hysteresis technique.

[0378] In some embodiments, the system is configured to generate the first and second voltage waveforms according to a pulse width modulation technique. The control circuit may be configured to control the switch circuit under balanced phase conditions so that the interconnection module supplies energy to both the first array and the second array. The energy supplied to the first array may be the same as the energy supplied to the second array. The control circuit may be configured to modulate the operating frequency of the switch circuit to adjust the energy supplied to the first array by the energy source relative to the energy supplied to the second array. The control circuit may be configured to cause the interconnection module to output relatively more energy to the first array under unbalanced phase conditions compared to balanced phase conditions. The control circuit may be configured to cause one or more modules of the first array to output relatively less energy under unbalanced phase conditions compared to balanced phase conditions. The control circuit may be configured to maintain the same energy output by one or more modules of the second array and by the interconnection module to the second array under unbalanced phase conditions compared to balanced phase conditions. The control circuit may be configured to cause the interconnection module to output relatively less energy to the second array under unbalanced phase conditions compared to balanced phase conditions, and cause one or more modules of the second array to output relatively more energy.

[0379] The control circuit may be configured to cause relatively less energy to be output by the interconnected modules to the first array under unbalanced phase conditions compared to balanced phase conditions. The control circuit may be configured to cause relatively more energy to be output by one or more modules of the first array under unbalanced phase conditions compared to balanced phase conditions.

[0380] In many of the aforementioned embodiments, the control circuit may include a master control device and a local control device communicatively coupled to the master control device. The master control device may be configured to determine whether the first array and the second array are in an unbalanced condition. The master control device may be configured to cause the local control device to generate one or more control signals for the switching circuit, the control signals causing the energy supplied by the energy source to one of the first array and the second array to be adjusted. The master control device may be configured to modulate a normalized reference signal and output the modulated signal to the local control device. The master control device may be configured to output a reference signal and a modulation index to the local control device, and the local control device may be configured to adjust the reference signal based on the modulation index. The control circuit may be configured to perform phase balancing by adjusting one or more modulation indices.

[0381] In some embodiments, the load is a primary load and the interconnect module is configured to be electrically coupled to an auxiliary load. The interconnect module may include a switching circuit coupled to the inductor to regulate a voltage supply to the auxiliary load.

[0382] In some embodiments, the load is a primary load and the interconnect module is configured to be electrically coupled to an auxiliary load, and the control circuit can be configured to measure the voltage and / or current of the auxiliary load and control the switching circuit of the interconnect module to adjust the voltage or current supply to the auxiliary load.

[0383] In some embodiments, each module of the first array includes an energy source and a switching circuit, and each module of the second array includes an energy source and a switching circuit.

[0384] In some embodiments, each module in the system includes a local control device and a common housing, and the switching circuit, energy source and local control device of the module are housed in the common housing.

[0385] In some embodiments, each module in the system includes a local control device, a first housing, and a second housing, and the local control device and the switching circuit of the module are located in the first housing, and the energy source of the module is located in the second housing, and the first and second housings are physically connected to each other.

[0386] In some embodiments, each module in the system includes a local control device, a first housing, a second housing, and a third housing, wherein the local control device of the module is located in the first housing, the switching circuit of the module is located in the second housing, and the energy source of the module is located in the third housing, and the first, second and third housings are physically connected together.

[0387] In some embodiments, for each module of the system, the switching circuit and the local control device are located on a first printed circuit board.

[0388] In some embodiments, the control circuit is configured to: determine the amount of interphase imbalance between the first array and the second array; if below a threshold, cause the interconnection module to adjust the net energy output to reduce the amount of interphase imbalance; and if above a threshold, cause a shift toward a neutral point of the system to adjust the net energy output to reduce the amount of interphase imbalance. The control circuit may also be configured to: if the amount of interphase imbalance is above a threshold, cause the interconnection module to adjust the net energy output to help reduce the amount of interphase imbalance.

[0389] In many embodiments, a method for phase balancing in a system is provided, wherein the system includes: a first array of cascaded modules, configured to output a first voltage waveform to a load; a second array of cascaded modules, configured to output a second voltage waveform to the load, wherein the first and second voltage waveforms each have a different phase angle; an interconnection module coupled to both the first array and the second array; and a control circuit, and the method includes: determining, by the control circuit, that an unbalanced condition exists between the first array and the second array; and adjusting energy supplied to the first array from an energy source of the interconnection module.

[0390] In some embodiments, adjusting the energy supplied from the energy source includes increasing the net energy supplied from the energy source. The method may further include reducing the net energy output by at least one module of the first array. An increase in net energy may be equivalent to a decrease in net energy. The method may further include reducing the net energy supplied by all modules of the first array. The method may further include maintaining the relative amount of net energy output from the interconnected modules to the second array and from the modules of the second array at a constant level.

[0391] In some embodiments, the method further comprises: reducing the net energy output from the interconnected modules to the second array; and increasing the net energy output of at least one module of the second array.

[0392] In some embodiments, the method further includes increasing a modulation index of a switch circuit coupled to an interconnected module of the first array to increase a net energy supplied to the first array from an energy source of the interconnected module. The method may further include decreasing a modulation index of at least one module of the first array to decrease a net energy output by at least one module of the first array.

[0393] In some embodiments, the unbalanced condition is that the first array has a relatively lower overall energy level than the second array.

[0394] In some embodiments, the method further includes receiving, by the control circuit, charge state information from each module of the first array and the second array; and determining, by the control circuit, whether the first array has a relatively lower overall charge state before increasing the net energy supplied to the first array from the energy sources of the interconnected modules.

[0395] In some embodiments, the unbalanced condition is that the first array has a relatively higher temperature than the second array.

[0396] In some embodiments, the method further includes receiving temperature information from each module of the first array and the second array; and determining whether the first array has a relatively higher temperature than the second array before increasing the net energy supplied to the first array from the energy sources of the interconnected modules.

[0397] In some embodiments, the control circuit is configured to control a balance of inter-phase energy between the first array and the second array using the interconnect module.

[0398] In some embodiments, the control circuit includes a master control device and a local control device communicatively coupled to the master control device. The method may further include determining, by the master control device, whether the first array and the second array are in an unbalanced condition. The method may further include causing the local control device to generate one or more control signals for the switch circuit, the control signals causing an adjustment to be made to an energy supplied to one of the first array and the second array by the interconnect module. The method may further include modulating the normalized reference signal and outputting the modulated signal to the local control device. The method may further include outputting the reference signal and the modulation index to the local control device; and adjusting the reference signal based on the modulation index.

[0399] In some embodiments, the load is a primary load, and the method further includes providing a voltage from the interconnect module to the auxiliary load. The method may further include regulating the voltage supplied by the interconnect module to the auxiliary load. The method may further include measuring the voltage and / or current of the auxiliary load; and controlling a switching circuit of the interconnect module to regulate the voltage supplied to the auxiliary load.

[0400] In some embodiments, adjusting the energy supplied to the first array from the energy source of the interconnected module includes reducing the net energy supplied from the energy source. The interconnected module may supply energy to both the first array and the second array during a balanced condition. The method may further include increasing the net energy output by at least one module of the first array. An increase in net energy is equivalent to a decrease in net energy. The method may further include increasing the net energy supplied by all modules of the first array. The method may further include maintaining the relative amount of net energy output from the interconnected module to the second array and from the modules of the second array at a constant level. The method may further include increasing the net energy output from the interconnected module to the second array; and reducing the net energy output by at least one module of the second array. The method may further include reducing the modulation index of a switching circuit coupled to the interconnected module of the first array so as to reduce the net energy supplied to the first array from the energy source of the interconnected module.

[0401] In some embodiments, the method further includes determining or estimating, by the control circuit, an energy output adjustment that causes the first array and the second array to converge to an equilibrium condition.

[0402] In some embodiments, the imbalance condition is related to state of charge, temperature, capacity, state of health, voltage, and / or current.

[0403] In some embodiments, the method further includes controlling a balance of interphase energy between the first array and the second array using the interconnect module and the neutral point offset.

[0404] In some embodiments, the first and second voltage waveforms are generated according to pulse width modulation or hysteresis techniques.

[0405] In some embodiments, the interconnect module supplies energy to both the first array and the second array during equilibrium conditions.

[0406] In some embodiments, the method further comprises performing inter-phase balancing by adjusting one or more modulation indices.

[0407] In some embodiments, determining, by the control circuit, that an unbalanced condition exists between the first array and the second array includes referencing one or more types of qualitative or quantitative information.

[0408] In some embodiments, determining by the control circuit that an imbalance condition exists between the first array and the second array includes referencing a SOC parameter of one array or characterizing that a SOC parameter of one array is less than, greater than, or substantially different than a SOC parameter of at least one different array or the system as a whole.

[0409] In some embodiments, determining by the control circuit that an unbalanced condition exists between the first array and the second array includes referencing a temperature parameter of one array or characterizing that a temperature parameter of one array is less than, greater than, or substantially different than a temperature parameter of at least one different array or the system as a whole.

[0410] In some embodiments, determining, by the control circuit, that an imbalance condition exists between the first array and the second array includes referencing a state of health (SOH) parameter of one array or characterizing that a state of health (SOH) parameter of one array is less than, greater than, or substantially different than a SOH parameter of at least one different array or the system as a whole.

[0411] In some embodiments, determining by the control circuit that an unbalanced condition exists between the first array and the second array includes referencing a voltage parameter of one array or characterizing that a voltage parameter of one array is less than, greater than, or substantially different than a voltage parameter of at least one different array or the system as a whole.

[0412] In some embodiments, determining by the control circuit that an unbalanced condition exists between the first array and the second array includes referencing a current parameter of one array or characterizing that a current parameter of one array is less than, greater than, or substantially different than a current parameter of at least one different array or the system as a whole.

[0413] In some embodiments, determining by the control circuit that an unbalanced condition exists between the first array and the second array includes a reference fault or degradation condition.

[0414] In some embodiments, the determination that an unbalanced condition exists between the first array and the second array is based on a relative difference or an absolute factor between the first array and the second array.

[0415] In some embodiments, the method further comprises: determining an amount of phase imbalance between the first array and the second array; if below a threshold, adjusting a net energy output of the interconnected module to reduce the amount of phase imbalance; and if above a threshold, shifting a neutral point of the system to adjust the net energy output to reduce the amount of phase imbalance. In some embodiments, the method further comprises: if above a threshold, adjusting the net energy output of the interconnected module to help reduce the amount of phase imbalance.

[0416] In many embodiments, a control system is provided that is configured to provide control of a module-based energy storage system, the module-based energy storage system comprising: a first array of cascaded modules configured to output a first voltage waveform to a load; a second array of cascaded modules configured to output a second voltage waveform to the load, wherein the first and second voltage waveforms each have a different phase angle; and an interconnected module coupled to both the first array and the second array, wherein the control system comprises: a control circuit and a non-volatile memory communicatively coupled to the control circuit, wherein a plurality of instructions are stored on the memory, and when executed by the control circuit, the plurality of instructions cause the control circuit to: determine that an unbalanced condition exists between the first array and the second array; and cause an adjustment to be made to energy supplied to the first array from an energy source of the interconnected module.

[0417] In some embodiments, the plurality of instructions further cause the control circuit to cause an increase in net energy supplied to the first array from the energy sources of the interconnected modules. The plurality of instructions may further cause the control circuit to cause a decrease in net energy output by at least one module of the first array. An increase in net energy may be equivalent to a decrease in net energy. The plurality of instructions may further cause the control circuit to cause a decrease in net energy supplied by all modules of the first array. The plurality of instructions may further cause the control circuit to cause the relative amounts of net energy output from the interconnected modules to the second array and from the modules of the second array to be at a constant level. The plurality of instructions may further cause the control circuit to cause a decrease in net energy output from the interconnected modules to the second array and an increase in net energy output by at least one module of the second array.

[0418] In some embodiments, the plurality of instructions may further cause the control circuit to increase a modulation index of a switch circuit coupled to an interconnected module of the first array so as to increase a net energy supplied to the first array from an energy source of the interconnected module. The plurality of instructions may further cause the control circuit to decrease a modulation index of at least one module of the first array so as to reduce a net energy output by at least one module of the first array.

[0419] In some embodiments, the unbalanced condition is that the first array has a relatively lower overall energy level than the second array.

[0420] In some embodiments, the plurality of instructions further cause the control circuit to determine whether the first array has a relatively lower overall state of charge before causing a net increase in energy supplied to the first array from an energy source of the interconnect module.

[0421] In some embodiments, the unbalanced condition is that the first array has a relatively higher temperature than the second array.

[0422] In some embodiments, the plurality of instructions further cause the control circuit to determine whether the first array has a relatively higher temperature than the second array before causing a net increase in energy supplied to the first array from an energy source of the interconnect module.

[0423] In some embodiments, the plurality of instructions further cause the control circuit to cause balancing of inter-phase energy between the first array and the second array.

[0424] In some embodiments, the control circuit includes a master control device and a local control device communicatively coupled to the master control device. The plurality of instructions may further cause the control circuit to generate one or more control signals for the switch circuit, the control signals causing the energy supplied by the interconnect module to one of the first array and the second array to be adjusted.

[0425] In some embodiments, the plurality of instructions may further cause the control circuit to modulate the normalized reference signal with a modulation index.

[0426] In some embodiments, the load is a primary load, and the plurality of instructions further cause the control circuit to adjust a voltage supplied from the interconnect module to the auxiliary load. The plurality of instructions may further cause the control circuit to control a switch circuit of the interconnect module to adjust the voltage supplied to the auxiliary load.

[0427] In some embodiments, the plurality of instructions further cause the control circuit to reduce the net energy supplied to the first array from the energy source of the interconnected module. The plurality of instructions may further cause the control circuit to cause the interconnected module to supply energy to both the first array and the second array during a balanced condition. The plurality of instructions may further cause the control circuit to cause an increase in the net energy output by at least one module of the first array. An increase in net energy is equivalent to a decrease in net energy. The plurality of instructions may further cause the control circuit to increase the net energy supplied by all modules of the first array. The plurality of instructions may further cause the control circuit to cause the relative amount of net energy output from the interconnected module to the second array and from the modules of the second array to be maintained at a constant level. The plurality of instructions may further cause the control circuit to: increase the net energy output from the interconnected module to the second array; and reduce the net energy output by at least one module of the second array. The plurality of instructions may further cause the control circuit to reduce the modulation index of the switching circuit coupled to the interconnected module of the first array so as to reduce the net energy supplied to the first array from the energy source of the interconnected module.

[0428] In some embodiments, the plurality of instructions further cause the control circuit to determine or estimate an energy output adjustment that causes the first array and the second array to converge to an equilibrium condition.

[0429] In some embodiments, the plurality of instructions further cause the control circuit to be in an unbalanced condition related to state of charge, temperature, capacity, state of health, voltage and / or current.

[0430] In some embodiments, the plurality of instructions further cause the control circuit to control the energy storage system to generate the first and second voltage waveforms according to a pulse width modulation or hysteresis technique.

[0431] In some embodiments, the plurality of instructions further cause the control circuit to cause the interconnect module to supply energy to both the first array and the second array during a balanced condition.

[0432] In some embodiments, the plurality of instructions further cause the control circuit to control the system to converge toward an inter-phase balance condition by adjusting a modulation index of the system.

[0433] In some embodiments, the plurality of instructions further cause the control circuit to determine that an imbalance condition exists between the first array and the second array by reference to a SOC parameter of one array or a SOC parameter characterizing one array that is less than, greater than, or substantially different than a SOC parameter of at least one different array or the system as a whole.

[0434] In some embodiments, the plurality of instructions further cause the control circuit to determine that an imbalance condition exists between the first array and the second array by reference to a temperature parameter of one array or a temperature parameter characterizing one array that is less than, greater than, or substantially different than a temperature parameter of at least one different array or the system as a whole.

[0435] In some embodiments, the plurality of instructions further cause the control circuit to determine that an unbalanced condition exists between the first array and the second array by reference to a fault or degradation condition.

[0436] In some embodiments, the plurality of instructions further cause the control circuit to control a balance of phase-to-phase energy between the first array and the second array using the interconnect module and the neutral point offset.

[0437] In some embodiments, the plurality of instructions further cause the control circuit to: determine an amount of interphase imbalance between the first array and the second array; if below a threshold, cause the interconnection module to adjust the net energy output to reduce the amount of interphase imbalance; and if above a threshold, cause a shift toward a neutral point of the system to adjust the net energy output to reduce the amount of interphase imbalance. The plurality of instructions may further cause the control circuit to: if the amount of interphase imbalance is above a threshold, also use the interconnection module to adjust the net energy output to reduce the amount of interphase imbalance.

[0438] In some embodiments, the processing circuitry includes a plurality of processors and the memory includes a plurality of discrete memory devices.

[0439] In many embodiments, a module-based energy system is provided, the system comprising: a first array of cascaded modules, configured to output a first voltage waveform to a load; a second array of cascaded modules, configured to output a second voltage waveform to the load; a third array of cascaded modules, configured to output a third voltage waveform to the load, wherein the first, second and third voltage waveforms each have a different phase angle; a first interconnected module coupled to both the first array and the second array, wherein the first interconnected module comprises a first energy source and a first switching circuit; and a second interconnected module coupled to the third array, wherein the second interconnected module comprises a second energy source and a second switching circuit, wherein the first and second energy sources are electrically coupled together, and wherein the first interconnected module is configured to adjust the amount of energy supplied by the first and second energy sources to the first and / or second arrays, and wherein the second interconnected module is configured to adjust the amount of energy supplied by the first and second energy sources to the third array.

[0440] In some embodiments, the first array and the second array are electrically positioned between the load and the first interconnect module, and the third array is electrically positioned between the load and the second interconnect module.

[0441] In some embodiments, the system further includes a control circuit configured to control first and second switch circuits, wherein the first energy source has a positive node and a negative node shared with the second energy source, and wherein the first switch circuit is controllable to selectively couple the first and / or second arrays to the first and / or second nodes, and the second switch circuit is controllable to selectively couple the third array to the first and / or second nodes. The control circuit can be configured to control the first and second switch circuits to adjust the relative energy output from the first and second energy sources to one of the first, second, and third arrays, thereby mitigating an imbalance in charge or temperature between at least two of the first, second, and third arrays. The control circuit can be configured to control the balance of phase energy between the first, second, and third arrays using a shift to the neutral point of the first, second, and third arrays. The control circuit can be configured to control the first and second switch circuits under balanced phase conditions so that the first interconnection module supplies energy to both the first and second arrays, and the second interconnection module supplies energy to the third array. The net energy supplied to the first, second, and third arrays can be the same over a period of time.

[0442] In many embodiments, a module-based energy system is provided, the system comprising: a first battery pack including a first plurality of arrays of cascade converter modules, the first plurality of arrays of cascade converter modules being configured to output a first plurality of voltage waveforms to power a first motor, each of the first plurality of voltage waveforms having a different phase angle; a second battery pack including a second plurality of arrays of cascade converter modules, the second plurality of arrays of cascade converter modules being configured to output a second plurality of voltage waveforms to power a second motor, each of the second plurality of voltage waveforms having a different phase angle; and an interconnection module coupled to a first array of the first plurality of arrays and a second array of the second plurality of arrays, wherein the interconnection module comprises an energy source and a switching circuit, wherein the interconnection module is configured to adjust the amount of energy supplied by the energy source to the first and / or second arrays.

[0443] In some embodiments, the first battery pack includes a first housing and the first plurality of arrays are co-located in the first housing, and wherein the second battery pack includes a second housing and the second plurality of arrays are co-located in the second housing. The interconnect module may be located in the first housing.

[0444] In some embodiments, the first and second electric machines are in-wheel electric machines of an electric vehicle.

[0445] In many embodiments, the system further includes a control circuit configured to monitor operating parameters of the first and second battery packs and cause the system to balance energy between the first battery pack and the second battery pack using the interconnect module. The control circuit can be configured to control the switch circuit so that under an unbalanced condition between the first array and the second array, the energy source releases relatively more energy to the first array than to the second array.

[0446] In some embodiments, the interconnect module is a first interconnect module, the energy source is a first energy source, and the switch circuit is a first switch circuit, the system further comprising: a third battery pack including a third plurality of arrays of cascade converter modules, the third plurality of arrays of cascade converter modules being configured to output a third plurality of voltage waveforms to power a third motor, each of the third plurality of voltage waveforms having a different phase angle; a fourth battery pack including a fourth plurality of arrays of cascade converter modules, the fourth plurality of arrays of cascade converter modules being configured to output a fourth plurality of voltage waveforms to power a fourth motor, each of the fourth plurality of voltage waveforms having a different phase angle; and a second interconnect module coupled to a third array of the third plurality of arrays and a fourth array of the fourth plurality of arrays, wherein the second interconnect module includes a second energy source and a second switch circuit, wherein the second interconnect module is configured to adjust the amount of energy supplied by the second energy source to the third and / or fourth arrays. The first, second, third, and fourth motors may be in-wheel motors of a four-wheel electric vehicle.

[0447] The processing circuitry may include one or more processors, microprocessors, controllers, and / or microcontrollers, each of which may be a discrete or independent chip, or distributed across multiple different chips (and portions thereof). Any type of processing circuitry may be implemented, such as, but not limited to, a personal computing architecture (e.g., such as used in a desktop PC, laptop computer, tablet computer, etc.), a programmable gate array architecture, a proprietary architecture, a custom architecture, and the like. The processing circuitry may include a digital signal processor, which may be implemented in hardware and / or software. The processing circuitry may execute software instructions stored on a memory that cause the processing circuitry to take many different actions and control other components.

[0448] The processing circuitry may also execute other software and / or hardware routines. For example, the processing circuitry may interface with the communication circuitry and perform analog-to-digital conversion, encoding and decoding, other digital signal processing, multimedia functions, convert data into a format suitable for providing to the communication circuitry (e.g., in-phase and quadrature), and / or may cause the communication circuitry (wired or wireless) to transmit data.

[0449] Any and all signals described herein may be wirelessly communicated unless otherwise specified or logically unreasonable. Communication circuits for wireless communication may be included. The communication circuit may be implemented as one or more chips and / or components (e.g., transmitters, receivers, transceivers, and / or other communication circuits) that perform wireless communication over a link under an appropriate protocol (e.g., Wi-Fi, Bluetooth, Bluetooth low energy, near field communication (NFC), radio frequency identification (RFID), proprietary protocols, etc.). As required, one or more other antennas may be included in the communication circuit to operate with various protocols and circuits. In some embodiments, the communication circuit may share an antenna for transmission over the link. The processing circuit may also interface with the communication circuit to perform the reverse function necessary to receive the wireless transmission and convert it into digital data, voice, and / or video. The RF communication circuit may include a transmitter and a receiver (e.g., integrated as a transceiver) and associated encoder logic.

[0450] The processing circuitry may also be adapted to execute an operating system and any software applications, and to perform those other functions unrelated to the processing of transmitted and received communications.

[0451] Computer program instructions for carrying out operations in accordance with the described subject matter may be written in any combination of one or more programming languages, including object-oriented programming languages ​​such as Java, JavaScript, Smalltalk, C++, C#, Transact-SQL, XML, PHP, etc., as well as conventional procedural programming languages ​​such as the "C" programming language or similar programming languages.

[0452] The memory, storage, and / or computer-readable medium may be shared by one or more of the various functional units present, or may be distributed between two or more of them (e.g., as separate memories present in different chips). The memory may also be its own separate chip.

[0453] To the extent that the embodiments disclosed herein include or operate in association with memory, storage, and / or computer-readable media, the memory, storage, and / or computer-readable media are non-transitory. Thus, to the extent that memory, storage, and / or computer-readable media are covered by one or more claims, the memory, storage, and / or computer-readable media are only non-transitory. The terms "non-transitory" and "tangible" as used herein are intended to describe memory, storage, and / or computer-readable media other than propagating electromagnetic signals, but are not intended to limit the types of memory, storage, and / or computer-readable media in terms of persistence or other aspects of the storage. For example, "non-transitory" and / or "tangible" memory, storage, and / or computer-readable media include volatile and non-volatile media, such as random access media (e.g., RAM, SRAM, DRAM, FRAM, etc.), read-only media (e.g., ROM, PROM, EPROM, EEPROM, flash memory, etc.), and combinations thereof (e.g., hybrid RAM and ROM, NVRAM, etc.), and variations thereof.

[0454] It should be noted that all features, elements, components, functions, and steps described for any embodiment provided herein are intended to be freely combinable and replaceable with features, elements, components, functions, and steps from any other embodiment. If a feature, element, component, function, or step is described only for one embodiment, it should be understood that the feature, element, component, function, or step can be used with every other embodiment described herein, unless otherwise expressly stated. Therefore, this paragraph serves at all times as a prior basis and written support for the introduction of a claim that combines features, elements, components, functions, and steps from different embodiments, or replaces features, elements, components, functions, and steps from one embodiment with features, elements, components, functions, and steps from another embodiment, even if the following description does not expressly state that such a combination or replacement is possible in a particular case. It is clearly acknowledged that an explicit recitation of every possible combination and replacement would be overly cumbersome, especially considering that the permissibility of each and every such combination and replacement would be readily recognized by a person of ordinary skill in the art.

[0455] As used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0456] Although the embodiments are susceptible to various modifications and alternative forms, specific examples thereof have been shown in the drawings and described in detail herein. However, it should be understood that these embodiments are not limited to the specific forms disclosed, but rather, these embodiments will cover all modifications, equivalents, and alternatives that fall within the spirit of the present disclosure. In addition, any features, functions, steps, or elements of the embodiments may be stated in or added to the claims, as well as negative limitations that limit the scope of the invention of the claims by features, functions, steps, or elements that are not within the scope.

Claims

1. A module-based energy system comprising: a first array of cascaded modules, wherein each module in the first array is switchably connected to at least one other module of the first array to generate a first multi-level voltage waveform for a load; a second array of cascaded modules, wherein each module in the second array is switchably connected to at least one other module of the second array to generate a second multi-level voltage waveform for the load, wherein the first and second multi-level voltage waveforms each have a different phase angle; an interconnect module coupled to both the first array and the second array, wherein the interconnect module includes an energy source and a switching circuit, and wherein the interconnect module is configured to adjust an amount of energy supplied by the energy source to the first and / or second array; as well as a control circuit configured to detect an unbalanced condition between the first array and the second array and control the switch circuit to selectively couple the energy source to the first and / or second array, The control circuit includes a master control device and a plurality of local control devices communicatively coupled to the master control device, and each module of the system is associated with at least one of the plurality of local control devices.

2. The system of claim 1 , wherein all of the cascade modules of the first array and the second array are located between the load and the interconnection module, so that current from the interconnection module to the load will pass through all of the cascade modules of the first array at a first time and through all of the cascade modules of the second array at a second time.

3. The system according to claim 1, wherein: The master control device of the control circuit is configured to determine whether the first array and the second array are in an unbalanced condition.

4. The system according to claim 3, wherein: The master control device is configured to cause the local control device to generate one or more control signals for the switching circuit, the control signals causing adjustment of energy supplied by the energy source to one of the first and second arrays.

5. The system of claim 1, wherein the load is a primary load, and wherein the interconnect module is configured to electrically couple to an auxiliary load.

6. The system of claim 5, wherein the switching circuit is a first switching circuit, and wherein the interconnect module includes a second switching circuit coupled to the inductor to regulate the voltage supply to the auxiliary load.

7. The system of claim 1 , wherein the load is a primary load and the interconnect module is configured to be electrically coupled to an auxiliary load, and wherein the local control device is configured to evaluate a measured voltage and / or a measured current of the auxiliary load and, in response, control a switching circuit of the interconnect module to adjust a voltage or current supply to the auxiliary load.

8. The system of claim 1 , wherein the control circuit is configured to: determining an amount of interphase imbalance between the first array and the second array; If below a threshold, causing the interconnect module to adjust the net energy output to reduce the amount of phase imbalance; and If above a threshold, a shift towards the neutral point of the system is made to adjust the net energy output to reduce the amount of phase imbalance.

9. The system of claim 8, wherein the control circuit is configured to, if the amount of interphase imbalance is above a threshold, further cause the interconnect module to adjust the net energy output to help reduce the amount of interphase imbalance.

10. The system of claim 1, wherein: A first connection node electrically connects a first switch circuit output of the interconnect module to a first switch circuit output of a first module of the first array; The first switching circuit output of the interconnected module and the first switching circuit output of the first module are the only switching circuit outputs of the energy system electrically connected to the first connection node without passing through another module; The first array and the second array each have the same number of cascade modules; All cascaded modules of the first array are connected in series from the interconnection module to the load; and All cascaded modules of the second array are connected in series from the interconnect module to the load.

11. The system of claim 10, wherein the control circuit is configured to control the switch circuit such that, in response to the unbalanced condition, the energy source releases relatively more energy to the first array than to the second array.

12. The system of claim 1, wherein the imbalance condition is related to state of charge, temperature, capacity, state of health, voltage and / or current.

13. The system of claim 11, wherein the imbalance condition is that the first array has a relatively lower overall energy level than the second array.

14. The system according to claim 11, wherein: The master control device is configured to receive charge state information from each cascade module of the first and second arrays, determine whether the first array or the second array has a relatively lower overall charge state condition, and if so, cause the energy sources of the interconnected modules to release more energy to the one of the first array and the second array having the relatively lower overall charge state condition.

15. The system of claim 11, wherein the unbalanced condition is that the first array has a relatively higher temperature than the second array.

16. The system of claim 11, wherein the master control device is configured to receive temperature information from each cascade module of the first and second arrays, determine whether the first array or the second array has a relatively higher temperature, and cause the energy source of the interconnected modules to release more energy to the one of the first and second arrays having a relatively higher temperature.

17. The system of claim 11, wherein the control circuit is configured to control a balance of interphase energy between the first array and the second array using an energy source of the interconnected module.

18. The system of claim 11, wherein the control circuit is configured to control a balance of interphase energy between the first array and the second array using a shift toward a neutral point of the first array and the second array.

19. The system of claim 11, wherein the system is configured to generate the first and second voltage waveforms according to a pulse width modulation technique.

20. The system of claim 19, wherein the control circuit is configured to control the switch circuit under a balanced phase condition such that the interconnect module supplies energy to both the first array and the second array.

21. The system of claim 19, wherein the control circuit is configured to modulate an operating frequency of the switching circuit to adjust energy supplied to the first array relative to energy supplied to the second array by the energy source.

22. The system of claim 19, wherein the control circuit is configured to cause relatively more energy to be output by the interconnect module to the first array under unbalanced phase conditions compared to balanced phase conditions.

23. The system of claim 22, wherein the control circuit is configured to cause relatively less energy to be output by one or more modules of the first array under unbalanced phase conditions compared to balanced phase conditions.

24. The system of claim 23, wherein the control circuit is configured to maintain the same energy output by one or more modules of the second array and by the interconnected modules to the second array under unbalanced phase conditions compared to balanced phase conditions.

25. The system of claim 23, wherein the control circuit is configured to cause relatively less energy to be output by the interconnected modules to the second array under unbalanced phase conditions, and to cause relatively more energy to be output by one or more modules of the second array, compared to balanced phase conditions.

26. The system of claim 1, wherein the switch circuit of the interconnect module is a first switch circuit, the first switch circuit comprising: a first transistor pair controllable into a first state in which an energy source is connected to the first array and a second state in which the energy source is bypassed; and a second transistor pair controllable into a first state in which an energy source is connected to the first array and a second state in which the energy source is bypassed, wherein the interconnect module includes a third transistor pair connected to the inductor and controllable to regulate power to the auxiliary load, wherein all cascade modules of the first array are connected in series from the interconnection module to the load, and wherein all cascade modules of the second array are connected in series from the interconnection module to the load, wherein the master control device is configured to detect a charge imbalance between the first array and the second array and output information to a first local control device associated with the interconnect module, and Wherein the first local control device is configured to control the first and second transistor pairs based on the information to mitigate the imbalance.

27. A method of phase balancing in a system, the system comprising a first array of cascaded switchable modules configured to output a first multi-level voltage waveform for a load; a second array of switchable cascaded modules configured to output a second multi-level voltage waveform for the load, wherein the first and second multi-level voltage waveforms each have a different phase angle; interconnect modules including an energy source and a switching circuit configured to selectively couple the energy source to the first and / or second arrays; and a control circuit configured to control the switching circuit and including a master control device and a plurality of local control devices communicatively coupled to the master control device, wherein each module of the system is associated with one of the plurality of local control devices, the method comprising: determining, by the master control device, that an unbalanced condition exists between the first array and the second array; and Energy supplied to the first array from an energy source of the interconnect module is regulated.

28. The method of claim 27, wherein all of the cascade modules of the first array and the second array are located between the load and the interconnection module, so that current from the interconnection module to the load will pass through all of the cascade modules of the first array at a first time and through all of the cascade modules of the second array at a second time.

29. The method of claim 27, wherein: A first connection node electrically connects a first switch circuit output of the interconnect module to a first switch circuit output of a first module of the first array; The first switching circuit output of the interconnected module and the first switching circuit output of the first module are the only switching circuit outputs of the energy system electrically connected to the first connection node without passing through another module; The first array and the second array each have the same number of cascade modules; All cascaded modules of the first array are connected in series from the interconnection module to the load; and All cascaded modules of the second array are connected in series from the interconnect module to the load.

30. The method of claim 29, wherein adjusting the energy supplied by the energy source comprises increasing the net energy supplied by the energy source to the first array.

31. The method of claim 30, further comprising reducing the net energy output of at least one module of the first array.

32. The method of claim 31 , wherein a net increase in energy is equivalent to a net decrease in energy.

33. The method of claim 31 , further comprising reducing the net energy supplied by all modules of the first array.

34. The method of claim 31 further comprising maintaining the relative amounts of net energy output from the interconnected modules to and from the modules of the second array at a constant level while reducing the net energy output of at least one module of the first array.

35. The method of claim 30, further comprising reducing the net energy output from the interconnected modules to the second array and increasing the net energy output of at least one module of the second array when the unbalanced condition persists.

36. The method of claim 30, further comprising: increasing a modulation index of a switching circuit of an interconnect module coupled to the first array so as to increase a net energy supplied to the first array from an energy source of the interconnect module; and The modulation index of at least one module of the first array is reduced to reduce the net energy output of the at least one module of the first array.

37. The method of claim 30, wherein the unbalanced condition is that the first array has a relatively lower overall energy level than the second array or a relatively higher temperature than the second array.

38. The method of claim 30, further comprising: receiving, by the master control device, charge state information from local control devices of modules of the first and second arrays; and Prior to increasing the net energy supplied to the first array from the energy source of the interconnected module, a determination is made by the master control device whether the first array has a relatively lower overall state of charge.

39. The method of claim 30, further comprising: receiving, by the master control device, temperature information from local control devices of modules of the first and second arrays; and Prior to increasing the net energy supplied to the first array from the energy source of the interconnected module, a determination is made by the master control device whether the first array has a relatively higher temperature than the second array.

40. The method of claim 29, wherein the load is a primary load, and further comprising providing voltage from the interconnect module to the auxiliary load.

41. The method of claim 40, further comprising regulating a voltage provided by the interconnect module to the auxiliary load.

42. The method of claim 41, further comprising: Measuring voltage and / or current of auxiliary loads; and The switching circuits of the interconnect modules are controlled using a local control device to adjust the voltage supplied to the auxiliary load based on the measured voltage and / or current.

43. The method of claim 27, further comprising causing a first local control device associated with the interconnect module to generate one or more control signals for the switching circuitry, the control signals causing adjustment of energy supplied to the first array by an energy source of the interconnect module.

44. The method of claim 43, further comprising modulating the normalized reference signal and outputting the modulated signal to the first local control device, wherein the modulated signal is used to generate the one or more control signals.

45. The method of claim 43, further comprising: outputting a reference signal and a modulation index to a first local control device; and The reference signal is adjusted by a first local control device based on the modulation index, wherein the adjusted reference signal is used to generate the one or more control signals.

46. ​​The method of claim 27, further comprising determining or estimating, by the master control device, energy output adjustments that cause the first and second arrays to converge to an equilibrium condition.

47. The method of claim 27, wherein the imbalance condition is related to state of charge, temperature, capacity, state of health, voltage and / or current.

48. The method of claim 27, further comprising operating a control circuit to control an interphase energy balance between the first array and the second array using the interconnect module and the neutral point offset.

49. The method of claim 27, wherein the first and second multi-level voltage waveforms are generated according to a pulse width modulation technique.

50. The method of claim 27, further comprising supplying energy from the interconnect module to both the first and second arrays during equilibrium conditions.

51. The method of claim 27, wherein determining by the master control device that an unbalanced condition exists between the first array and the second array comprises a reference fault or degradation condition.

52. The method of claim 27, further comprising: determining, using a master control device, an amount of interphase imbalance between the first array and the second array; If below a threshold, adjusting the net energy output of the interconnected modules to reduce the amount of phase imbalance; as well as If above a threshold, a shift is made towards the neutral point of the system to adjust the net energy output to reduce the amount of phase imbalance.

53. The method of claim 52, further comprising adjusting the net energy output of the interconnected modules to help reduce the amount of phase imbalance if above a threshold.

54. A control system configured to provide control for a module-based energy storage system, the module-based energy storage system comprising a first array of cascaded switchable modules configured to output a first multi-level voltage waveform to a load; a second array of cascaded switchable modules configured to output a second multi-level voltage waveform to a load, wherein the first and second voltage waveforms each have a different phase angle; and an interconnect module including an energy source and a switching circuit configured to selectively couple the energy source to the first and / or second arrays, the control system comprising: a plurality of local control devices associated with all modules of the energy storage system; and a master control device communicatively coupled to the plurality of local control devices, the master control device comprising a non-transitory memory, wherein a plurality of instructions are stored on the non-transitory memory, and when executed by the master control device, the plurality of instructions cause the master control device to: determining that an unbalanced condition exists between the first array and the second array; and Information is output to a first local control device of the interconnect module, the information instructing the first local control device to cause adjustment of energy supplied to the first array from an energy source of the interconnect module.

55. The control system of claim 54, wherein the plurality of instructions causes the master control device to instruct the first local control device to increase the net energy supplied to the first array from the energy source of the interconnected modules during an unbalanced condition.

56. The control system of claim 55, wherein the plurality of instructions causes the master control device to instruct at least one module of the first array to reduce net energy output during an unbalanced condition.

57. A control system as claimed in claim 56, wherein an increase in net energy is equivalent to a decrease in net energy.

58. The control system of claim 55, wherein the plurality of instructions cause the master control device to instruct all modules of the first array to reduce their net energy output during an unbalanced condition.

59. The control system of claim 55, wherein the plurality of instructions cause the master control device to instruct the interconnected modules to maintain a constant net energy output to the second array during an unbalanced condition and to instruct the modules of the second array to maintain a constant net energy output.

60. The control system of claim 55, wherein the plurality of instructions cause the master control device to instruct the interconnected modules to decrease net energy output to the second array during an unbalanced condition and to instruct at least one module of the second array to increase net energy output.

61. A control system according to claim 55, wherein the plurality of instructions causes the master control device to increase the modulation index of the switching circuit coupled to the interconnected module of the first array during an unbalanced condition so as to increase the net energy supplied to the first array from the energy source of the interconnected module.

62. The control system of claim 61, wherein the plurality of instructions cause the master control device to reduce the modulation index of at least one module of the first array during an unbalanced condition to reduce the net energy output of at least one module of the first array.

63. The control system of claim 61, configured to provide control for a module-based energy storage system, wherein all of the cascaded modules of a first array and a second array are located between a load and an interconnected module such that current from the interconnected module to the load will pass through all of the cascaded modules of the first array at a first time and through all of the cascaded modules of the second array at a second time.

64. The control system of claim 61, configured to provide control for a module-based energy storage system, wherein: A first connection node electrically connects a first switch circuit output of the interconnect module to a first switch circuit output of a first module of the first array; The first switching circuit output of the interconnected module and the first switching circuit output of the first module are the only switching circuit outputs of the energy system electrically connected to the first connection node without passing through another module; The first array and the second array each have the same number of cascade modules; All cascaded modules of the first array are connected in series from the interconnection module to the load; and All cascaded modules of the second array are connected in series from the interconnect module to the load.

65. The control system of claim 55, wherein the unbalanced condition is that the first array has a relatively lower overall energy level than the second array.

66. A control system according to claim 55, wherein the plurality of instructions cause the master control device to determine whether the first array has a relatively lower overall state of charge before instructing the first local control device to increase the net energy supplied to the first array from the energy source of the interconnected module during an unbalanced condition.

67. The control system of claim 55, wherein the unbalanced condition is when the first array has a relatively higher temperature than the second array.

68. A control system according to claim 55, wherein the plurality of instructions cause the master control device to determine whether the first array has a relatively higher temperature than the second array before instructing the first local control device to increase the net energy supplied to the first array from the energy source of the interconnected module during an unbalanced condition.

69. The control system of claim 54, wherein the plurality of instructions cause the master control device to modulate the normalized reference signal using a modulation index and output the modulated normalized reference signal as information.

70. The control system of claim 54, wherein the plurality of instructions cause the master control device to output a normalized reference signal and a modulation index as information.

71. The control system of claim 54, wherein the plurality of instructions cause the master control device to cause the interconnect module to supply energy to both the first and second arrays during a balanced condition.

72. The control system of claim 54, wherein the plurality of instructions cause the master control device to determine or estimate energy output adjustments during an unbalanced condition that cause the first and second arrays to converge to a balanced condition.

73. The control system of claim 54, wherein the imbalance condition is related to state of charge, temperature, capacity, state of health, voltage and / or current.

74. The control system of claim 54, wherein the plurality of instructions cause the master control device to control the energy storage system to generate the first and second voltage waveforms according to a pulse width modulation technique.

75. The control system of claim 54, wherein the plurality of instructions cause a master control device to control the system to converge toward a phase-to-phase balance condition by adjusting a modulation index of the system.

76. The control system of claim 54, wherein the plurality of instructions cause the master control device to determine that an unbalanced condition exists between the first array and the second array by reference to a fault or degradation condition.

77. The control system of claim 54, wherein the plurality of instructions cause the master control device to control the interphase energy balance between the first array and the second array using the interconnect module and the neutral point offset.

78. The control system of claim 54, wherein the plurality of instructions cause the master control device to: determining an amount of interphase imbalance between the first array and the second array; If the amount of interphase imbalance is below a threshold, outputting information to the first local control device, the information instructing the first local control device to adjust the net energy output to reduce the amount of interphase imbalance; and If the amount of phase imbalance is above a threshold, a shift toward a neutral point of the system is made to adjust the net energy output to reduce the amount of phase imbalance.

79. The control system of claim 78, wherein the plurality of instructions further cause the master control device to: if the amount of phase imbalance is above a threshold, further use the interconnection module to adjust the net energy output to reduce the amount of phase imbalance.

80. The control system of claim 54, wherein the master control device includes processing circuitry configured to execute the plurality of instructions.

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