Module-based energy systems with converter source modules

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 circuitry 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] This application is a divisional application of an application with a filing date of March 27, 2020, an application number of 202080039799.9 and an invention name of “Module-based energy system with converter source module and related methods”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] 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

[0004] 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 interconnection and control of modules in module-based energy systems. Background Art

[0005] In many industries, energy systems with multiple energy sources or energy sinks are common. An 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 electronic devices 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 automotive performance. 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.

[0006] An EV includes various electrical systems associated with the powertrain, which include, among other things, batteries, chargers, and motor controls. A brief list of the current capabilities and shortcomings of these electrical systems is described below.

[0007] Conventional battery design

[0008] High voltage battery packs are typically organized as a series chain of lower voltage battery modules. Each such module further consists of 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 charge state 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, charge state, temperature and other performance-impacting indicators of individual battery cells, if that system even exists elsewhere in the car. 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 results in the need to replace 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.

[0009] Conventional charger design

[0010] The charging circuits are typically implemented in a separate onboard system. They stage the power from outside the EV in the form of an AC signal or a 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 the charge transfer or total charge achievable.

[0011] Conventional Motor Control Design

[0012] Conventional control includes 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 larger 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.

[0013] 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 is a need for improved systems, devices and methods for energy systems used in the vehicle industry and elsewhere. Summary of the invention

[0014] 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. A more complex configuration of each module is 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.

[0015] In many example embodiments, at least one energy source of the module may include a capacitor (such as a supercapacitor or ultracapacitor), a battery, and a fuel cell unit.

[0016] 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.

[0017] The various interconnect architectures of the example embodiments enable phase-to-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 the 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 interconnect 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, wherein 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) interconnected to a master control device (MCD) according to an embodiment of the present disclosure.

[0023] Figure 3 is a block diagram depicting another example embodiment of a converter-source module (ConSource V2) having an LCD interconnected 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 interconnected to an MCD and an optional auxiliary load 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 ) 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 0048. 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 3 Graph 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 for 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.23 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 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. 27 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 two three-phase motors and an auxiliary load 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 and 33B 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 are phasor diagrams of a three-phase structure with a common module with voltage balancing control with intra-phase and inter-phase balance through (A) a common module and (B) a common module and a 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) common module and neutral point offset.

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

[0059] Fig.38A and 38B Depicted Fig. 27 The example system shown in FIG. 1 is a phasor diagram of voltage balancing control with intra-phase and inter-phase balance through (A) a common module and (B) a common module and a 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) a common module and (B) a common module and a 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) a common module and (B) a common module and a neutral point offset.

[0062] Fig.41 and 42 is a block diagram depicting an example embodiment of a converter-source module.

[0063] Fig.43A and 43B is a schematic diagram depicting an example embodiment of components of a converter-source module mounted on one or more substrates. DETAILED DESCRIPTION

[0064] 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.

[0065] 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.

[0066] Application Examples

[0067] 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.

[0068] 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 for converting 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.

[0069] When describing embodiments herein, reference may be made to a particular mobile application (e.g., an electric vehicle (EV)) or a fixed application (e.g., a power 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 fixed application. Embodiments of systems for providing power to a motor may be used in both mobile and fixed applications. Although certain configurations may be more suitable for some applications than others, all example embodiments disclosed herein are capable of being used in both mobile and fixed applications unless otherwise noted.

[0070] Example Embodiment of a Module-Based Energy System

[0071] 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 may be used (e.g., N is greater than or equal to two). The converter-source modules 108 - referred to herein as "ConSource" modules - may be connected to each other in a variety of ways, such as by referring to Figure 15-29 For ease of explanation, Figures 1A-1C, the ConSource modules are shown connected in series, or as a one-dimensional array, where the Nth ConSource module is coupled to a load 101. Load 101 is an electrical load to which power is output when the system 100 is used to provide power. 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 load 101, the ConSource module 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.

[0072] exist Figure 1A In an embodiment of the present invention, the control circuit 102 is configured to control one or more ConSource modules 108 based on status information received from the same or different one or more ConSource modules. 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 ConSource module over time; however, other aspects may be controlled instead of or in addition to output power.

[0073] In many embodiments, the status information of each ConSource module in the system 100 will be transmitted to the control circuit 102, and the control circuit 102 will independently control each ConSource module 108-1...108-N based on the status information. Other variations are possible. For example, control of a particular ConSource module (or a subset of ConSource modules) can be based on the status information of the particular ConSource module (or a subset of ConSource modules), based on the status information of a different ConSource module that is not the particular ConSource module (or a subset of ConSource modules), based on the status information of all ConSource modules other than the particular ConSource module (or a subset of ConSource modules), based on the status information of the particular ConSource module (or a subset of ConSource modules) and the status information of at least one other ConSource module that is not the particular ConSource module (or a subset of ConSource modules), or based on the status information of all ConSource modules in the system 100.

[0074] As will be described herein, state information may be information about one or more aspects of each ConSource module. 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 a ConSource module or its components: state of charge (SOC) (e.g., the charge level of an 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 an energy source compared to its ideal condition), capacity, temperature, voltage, current, or the presence or absence of a fault. Each ConSource module 108-1...108-N 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.

[0075] Figure 1B Another example embodiment of the system 100 is depicted. Here, the control circuit 102 is implemented as a master control device 112 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 device 114 and the converter-source module 108.

[0076] 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.

[0077] Each of the communication paths or links 106, 115 and 116 can be a wired or wireless communication path or link that transmits data or information bidirectionally in parallel or serial manner. The data can be transmitted in a standard or custom format. In automotive applications, the communication path or link 115 can be configured to transmit data according to the FlexRay or CAN protocol.

[0078] In reference Figure 1B and 1C In the described embodiment, the local control device 114 receives status information from each ConSource module, or determines status information based on sensed or measured signals or data received from each ConSource module, 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 algorithmically based on the raw data. The master control device 112 can then use the status information of the ConSource module 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 ConSource module.

[0079] For example, the master control device 112 may receive status information indicating one or more of the following conditions under which a particular ConSource module (or component thereof) is operating relative to one or more other ConSource modules in the system 100: having a relatively low SOC, having a relatively low SOH, having a relatively low capacity, having a relatively low voltage, having a relatively low current, having a relatively high 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 ConSource module to be reduced (or in some cases, increased depending on the conditions). In this manner, the power output of a ConSource module operating at, for example, a higher temperature may be reduced in order to cause the temperature of the ConSource module to converge toward the temperature of one or more other ConSource modules.

[0080] In other embodiments, the determination of whether to adjust the operation of a particular ConSource module may be made by comparing the status information to a predetermined threshold, limit, or condition, and not necessarily by comparing the status of other ConSource modules. 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 ConSource module 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 ConSource module. Similarly, if the status information of a ConSource module 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 ConSource module. 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.

[0081] The local control device 114 can receive, process and transmit: signals from various sensors (e.g., temperature, voltage and current sensors) of the converter-source module; 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 can communicate with the main control device 112 and transmit corresponding control signals to and from the main control device 112.

[0082] In this manner, the master control device 112 can control the ConSource 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 ConSource modules 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 ConSource modules. The term "balancing" as used herein does not require absolute equality among the ConSource modules 108 or components thereof, 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 proactively reduce operational differences between ConSource modules that would otherwise exist.

[0083] 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 and a memory. Example implementations of the processing circuit and the memory are further described below. The communication path or link 106 may also include a wired power supply to directly supply operating power 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 converter source modules 108.

[0084] 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 processing circuits and memory, 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 converter source modules 108. In some embodiments, the operating power for each local control device 114 is supplied only by one or more converter source 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 converter-source modules 108 (e.g., such as through the power network of the car).

[0085] 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.

[0086] In some embodiments, control of the system 100 may be distributed between control circuits 102 that are dedicated or local to the system 100 and control circuits that are shared with other parts of the application. For example, in an automotive application, the master control device 112 may be implemented as part of another control device (e.g., an electronic control unit (ECU)) of the vehicle that has responsibility for one or more other automotive functions (e.g., motor control, driver interface control, traction control, etc.).

[0087] The control circuit 102 may have a communication interface for communicating with another control device of the application. For example, in an automotive application, the control circuit 102 (eg, the main control device 112) may output data or information about the system 100 to another control device (eg, ECU) of the vehicle.

[0088] Example Embodiment of a Converter-Source Module within a Module-Based System

[0089] Figure 2-4 Describes Figure 1B 108 or ConSource modules within the system 100 depicted in FIG. 100, wherein each ConSource module 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.

[0090] The ConSource module 108 may be implemented as a voltage converter or a current converter. For ease of description, the embodiments described herein are accomplished with reference to a voltage converter, although the embodiments are not limited thereto.

[0091] Figure 2 1 is a block diagram depicting an example embodiment of a ConSource module 108A within the system 100. This embodiment of the ConSource module 108A may be referred to herein as version 1 (ConSource V1) of the 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). The ConSource V1 108A is communicatively coupled to the LCD 114, which in turn is communicatively coupled to the MCD 112.

[0092] ConSource V1108A 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 supercapacitor 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 ).

[0093] The outputs out1 and out2 of the energy source 1 may be connected to the input terminals in1 and in2 of an energy buffer, respectively, which may include, but is not limited to, for example, one of the following elements and topologies, 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.

[0094] The outputs out1 and out2 of the energy buffer are connected to the inputs in1 and in2 of the converter V1, respectively. Figure 5A A schematic representation of an example embodiment of the converter V1206 is shown in FIG. In many embodiments, the converter V1206 may include at least four switches S3, S4, S5, S6, which may be configured as semiconductor switches, such as metal oxide semiconductor field effect transistors or MOSFETs (eg, Figure 4 ). Another switch example is an insulated gate bipolar transistor or IGBT. The semiconductor switch 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.

[0095] In this embodiment, the converter V1206 generates three different voltage outputs +VDCL, 0 and -VDCL by connecting the DC line voltage VDCL between its terminals in1 and in2 to its output terminals out1 and out2 via different combinations of switches S3, S4, S5 and S6. To obtain +VDCL, switches S3 and S6 are turned on, while -VDCL 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 voltage.

[0096] The control switching signals 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 embodiment of the present invention are generated in different ways. One method is to use space vector pulse width modulation SVPWM or sinusoidal pulse width modulation SPWM or their variants 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.

[0097] In some embodiments using pulse width modulation, the LCD (rather than the MCD) generates the switching signals for the switches in the ConSource module. In some embodiments, such as those using hysteresis, the generation of the switching signals may be performed by the MCD. Figure 2 The LCD 114 shown in FIG. 1 can be connected to the ConSource V1108A 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 V1206.

[0098] In one exemplary embodiment, the functions of managing the Energy Source 1 for the ConSource V1 module 108A 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.

[0099] In one exemplary embodiment, the LCD protection function for the energy buffer 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, 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; and / or IEB - current through at least one component of the energy buffer. Based on these measurement signals, 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 MCD 112.

[0100] In one example embodiment, the control and protection of the converter V1206 of the ConSource V1 module 108A by the LCD 114 functions as follows. The LCD may receive a command signal from the MCD (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 drive circuit (not shown) from the converter V1206 Figure 2 The LCD may be used for overcurrent protection together with one or more signals F (not shown) that may carry information about the fault state (e.g., short circuit or open circuit fault mode) of all switches in the converter V1. Based on this data, the LCD may make a decision about which combination of switch signals 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 particular switch may turn that switch on or off.)

[0101] 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 to LCD 114, which in turn is communicatively coupled to MCD 112.

[0102] In this embodiment, ConSource V2108B is in a dual energy source configuration with a primary energy source 1202 and a secondary energy source 2304. Energy source 1 may include, for example, but not limited to, one of the following: 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 ) and fuel, fuel cell unit or fuel cell unit module 620 ( Figure 6C ).

[0103] The outputs out1 and out2 of the energy source 1202 may be connected to the input terminals in1 and in2 of the energy buffer 204, which may include, but is not limited to, for example, one of the following elements and topologies, 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 outputs out1 and out2 of the energy buffer 204 are connected to the inputs in1 and in3 of the converter V2 308, respectively.

[0104] The output out2 of the energy buffer 204 may also be connected to the output out2 of the energy source 2304. Another output out1 of the energy source 2 is connected to the input in2 of the converter V2308. The energy source 2 may include, but is not limited to, for example, one of the following storage elements, such as: an electrolytic and / or film capacitor CEB 800 ( Fig. 8A ); supercapacitor or ultracapacitor 810 ( Figure 8B ); Battery module 820, including at least one battery cell or multiple battery cells connected in series and / or in parallel ( Figure 8C ); electrolytic and / or film capacitor CEB 800 connected in parallel with the supercapacitor or ultracapacitor 810 ( Fig.8D ); an electrolytic and / or film capacitor CEB 800 connected in parallel with the battery module 820, comprising at least one battery cell or a plurality of battery cells connected in series and / or in parallel ( Fig. 8E ); an electrolytic and / or film capacitor CEB 800 connected in parallel with a supercapacitor (or ultracapacitor) 810 and a battery module 820, comprising at least one battery cell or a plurality of battery cells connected in series and / or in parallel ( Fig.8F ).

[0105] Figure 5B A simplified schematic representation of an example embodiment of the converter V2308 is shown in FIG. Here, the converter V2308 includes six switches S1, S2, S3, S4, S5, S6, which can be configured as semiconductor switches, such as, for example, MOSFETs (e.g., Figure 5B The semiconductor switches can be operated at a high switching frequency, thereby permitting the converter V2308 to operate in pulse width modulation mode when required and to respond to control commands in short time intervals, thereby providing a high output voltage regulation tolerance and fast dynamic behavior in transient mode.

[0106] The left hand side of converter V2308 includes two switches S1 and S2 and can generate two different voltages at node 1, namely +VDCL and 0, referenced to input In3, which can be at virtual zero potential. Coupled inductor L C Connected between input In3 and node 1. The output out1 of energy source 2 is connected to the coupled inductor LC at the input In3 of converter V2308. The current consumed from or generated to energy source 2304 can be adjusted by adjusting the coupled inductor L C The voltage across the switches S1 and S2 may be controlled, for example using a pulse width modulation technique or a hysteresis control method for switching the switches S1 and S2. Other techniques may also be used.

[0107] The right hand side of the converter V2308 includes four switches S3, S4, S5, S6, and by connecting the DCL-voltage VDCL between the terminals in1 and in2 to the output terminals out1 and out2 via different combinations of switches S3, S4, S5, S6, three different voltage outputs, namely +VDCL, 0 and –VDCL, can be generated. In order to obtain the +VDCL voltage between out1 and out2, switches S3 and S6 are turned on, while the –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.

[0108] The control switching signals for the semiconductor switches S3, S4, S5, S6 may be generated in different ways depending on the flexibility and requirements of the control techniques employed in the LCD 114 and the MCD 112. One approach is to use pulse width modulation, such as space vector pulse width modulation (SVPWM) or sinusoidal pulse width modulation (SPWM), including additional variations thereof, to generate the output voltage of the converter V2. Fig. 9 A typical output voltage waveform 900 of converter V2 308 is shown in FIG. The modulation method also depends on which version of the ACi battery pack it is applied to, and one possible modulation solution will be further presented as an example.

[0109] In this example ConSource V2 module 108B, Energy Source 1202 acts as the primary energy source and thus supplies the average power required by the load. Energy Source 2304 may be a secondary energy source having the function of assisting Energy Source 1 by providing additional power at load power peaks or absorbing excess power.

[0110] Fig.10 An output voltage waveform 1000 from an example module-based energy storage system having six example converter-source modules is shown.

[0111] 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.

[0112] In these embodiments, power flow controller 11110 and power flow controller 21120 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 11110 and power flow controller 21120 may be shared or distributed between LCD 114 and MCD 112.

[0113] The power flow controller 11110 can receive a reference power flow signal (P ES1,REF ). This signal can 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 1202 of the ConSource V2 module 108B. The power flow controller 11110 can estimate the maximum allowable charging and / or discharging current of the energy source 1202 and calculate the actual allowable 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 21120. The power flow controller 21120 can calculate the coupled inductor L based on the voltage between the output terminals out1 and out2 of the energy source 2304. C The reference current in , and the switching signals of switches S1 and S2 of converter V2308 are determined using, for example but not limited to, pulse width modulation or hysteresis control algorithms. Therefore, the total power flow (P CONSOURCE ) can be provided by the switching portion of the converter V2, which includes switches S3, S4, S5, and 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) between the current values, where P ES2 Managed by the switching section of converter V2308, which includes switches S1, S2 and coupled inductor LC.

[0114] In many embodiments, energy source 2304 may be a secondary energy source and its function is to assist energy source 1 by providing power at load power peaks and / or absorbing excess power. The secondary function of energy source 2304 may be active filtering, such as reducing (attenuating) or eliminating any second-order current harmonics that appear 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. The harmonics may have considerable peak-to-peak values ​​that may be as high as twice the load current amplitude. The second-order current component exhibits some disadvantages, such as an increase in internal losses in energy source 1202 associated with the resulting current RMS value. To perform this secondary function, energy source 2304 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.

[0115] Fig. 12A and 12B 1 shows examples of waveforms 1200, 1220 that occur before and during the execution of the active filtering secondary function. Before compensation begins (before time t1), the energy source 1202 ( 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 1I 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 the energy source 1202 to maintain the voltage on the capacitor of the energy source 2304 and / or the ultracapacitor 810 at a set value, which is required for proper operation of the converter V2308.

[0116] Both the primary and secondary functions performed by converter V2 and described above may be performed separately or simultaneously. If simultaneously, the energy source 2304 preferably comprises an electrolytic capacitor or supercapacitor 810 (such as Fig. 8A , 8B and 8D-8F).

[0117] Figure 3 1 shows 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 the energy source 1202. The second function is the management of the energy source 2304. 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.

[0118] The management functions of the Energy Source 1 for the ConSource V2 module 108B may be as follows. The LCD 114 receives measurement signals VES1, TES1, IES1, which are: VES1 - voltages of all basic components / battery cells of the Energy Source 1 or voltages of groups of basic components / battery cells, such as, for example but not limited to, battery cells connected individually or in series and / or in parallel, supercapacitor cells connected individually or in series and / or in parallel; TES1 - temperatures of all basic components of the Energy Source 1 or temperatures of groups of basic components; 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 112.

[0119] The management functions of the energy source 2304 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.

[0120] The protection function for the energy buffer of the ConSource V2 module 108B may be as follows. The LCD 114 receives measurement signals VEB, TEB, IEB, which are: VEB - 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.

[0121] The control and protection functions of the converter V2 308 for 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 above-mentioned power management and / or second-order harmonic reduction techniques. 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 together with a signal F (not shown) for overcurrent protection, which 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 the converter V2 and the entire ConSource V2 module or disconnect from the system 100 (e.g., battery pack, etc.).

[0122] 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.

[0123] ConSource V3 module 108C may include energy source Energy Source 1202 and converter V2308 having an additional input for connecting auxiliary load 2410, such as Figure 4 , if desired. ConSource V3 module 108C has output ports 1 and 2 for connecting to other ConSource (e.g., V1 / V2 / V3) modules within example system 100. The illustrated output ports 3 and 4 of ConSource V3 are used to connect the example ConSource V3 module to the same output ports of other ConSource V3 modules of example system 100, if desired, and / or as shown. Figure 4 , for connection to auxiliary load 1408, if desired. The illustrated output ports 5 and 6 of 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 as Figure 4 , for connection to an auxiliary load 2410 if desired.

[0124] The energy source 1 may include, but is not limited to, one of the following storage elements, for example according to FIG. 6 : 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 ) and fuel, fuel cell unit or fuel cell module 620 ( Figure 6C )

[0125] The outputs out1 and out2 of the energy source 1202 are connected to the input terminals in1 and in2 of the energy buffer 204, respectively. The energy buffer 204 may include, but is not limited to, for example, one of the following components 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 outputs out1 and out2 of the energy buffer 204 are connected to the inputs in1 and in3 of the converter V2 308, respectively.

[0126] A simplified schematic representation of the converter V2308 is shown in Figure 5B The converter V2 includes six switches S1, S2, S3, S4, S5, S6, which can be configured as semiconductor switches, such as MOSFETs (eg Figure 5B ), JFET or IGBT. The left-hand side of converter V2 includes two switches S1 and S2, which can generate two different voltages at node 1, namely +VDCL and 0, with reference to input In3, which can be at virtual zero potential. Coupled inductor L C Connect between input In3 and node 1. Coupled inductor L C The output of is connected to port 5 of ConSource V3 module 108C and an optional auxiliary load 2410 via input In2 of converter V2308, such as Figure 4 As shown in . Assuming that the auxiliary load 2 has an input capacitor, the converter V2308 can regulate and stabilize the required constant voltage on the load, and regulate the voltage on the coupled inductor LC and the current through the coupled inductor LC.

[0127] The right hand side of the converter V2308 includes four switches S3, S4, S5, S6, and can generate three different voltage outputs +VDCL, 0 and –VDCL by connecting the DCL-voltage VDCL between the terminals in1 and in2 to the output terminals out1 and out2 through different combinations of switches S3, S4, S5, S6. In order to obtain the +VDCL voltage between out1 and out2, switches S3 and S6 are turned on, while the –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 reference potential.

[0128] 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 .

[0129] Energy source 1202 may supply a corresponding portion of the power required by the load of system 100 , auxiliary load 1408 , and / or auxiliary load 2410 (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.

[0130] 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 functions of PFC 1, PFC 2, PFE 1, and PFE 2 may be shared or distributed between the LCD and the MCD.

[0131] PFE 1 can receive power source 1202P from LCD 114 ES1,REF The reference power flow signal can be determined by the main power management controller located in the MCD 112 based on the load power demand and the state of the energy source 1 of this particular ConSource V3 module 108C. PFE1 can also receive the signal P LOAD1 , the signal P LOAD1 Determined by the power consumption and / or generation of the auxiliary load 1408 and in the power calculation block ( Fig.13 Energy Source 1202P TOT_REF_ES1 The total reference power flow can be P ES1,REF and P LOAD1 The PFC 11310 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 .

[0132] PFE 21320 can receive the 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 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 the auxiliary load 2 (e.g., measured by a current sensor that can be integrated in the ConSource V3 module, or received directly from the 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 the converter V2, which includes switches S3, S4, S5, and S6. LOAD2 can be managed by the switching part of the converter V2, which includes switches S1, S2 and coupled inductor L C .

[0133] Figure 4 108B and may perform at least one, preferably all, of four main functions. The first function may be the management of the energy source 1202. The second function may be the management of the auxiliary load 2410. The 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. The fourth function may be the control and protection of the converter V1.

[0134] In some example embodiments, the energy management function for the energy source 1202 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 1202, such as, for example but not limited to, battery cells connected individually or in series and / or in parallel, supercapacitor battery cells connected individually or in series and / or in parallel; TES1 - temperatures of all basic components of the energy source 1 or temperatures of groups of basic components; 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.

[0135] The management functions of the auxiliary load 2410 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. Based on these signals, the LCD performs a correction on the reference signal of the pulse width modulation in the LCD to stabilize and / or control the voltage on the auxiliary load 2.

[0136] 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; 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.

[0137] 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 4 The 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 V2308 and the entire ConSource V3 module from the system 100 (e.g., a battery pack, etc.).

[0138] An example of a ConSource module is a converter-battery module having a battery as a first energy source. A converter-battery module may be referred to as a ConBatt module. A 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.

[0139] 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.

[0140] Example embodiments of module arrangements for module-based systems

[0141] Figure 15-29 Example embodiments of the system 100 arranged according to various architectures or configurations are depicted. In these embodiments, the system 100 is referred to as a ConSource package, 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.

[0142] Fig.15 An example embodiment of a ConSource package 1500 according to the present disclosure is shown, which includes a one-dimensional array of N interconnected ConSource modules 108-1, 108-2, ... 108-N. Each ConSource module in the array can be configured according to the above reference. Figure 2 , 3and 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 ("a 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 ("a 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 out2 of the one-dimensional array 1500. The one-dimensional array of this number N interconnected 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.

[0143] The output voltage of the one-dimensional array of a number N of interconnected ConSource modules can be generated using, for example, but not limited to, space vector modulation or sinusoidal pulse width modulation ("PWM") using a phase-shifted carrier technique. The switching signals for the converter of each ConSource module can then be generated using the phase-shifted carrier technique. This technique ensures that the ConSource modules rotate continuously and that power is distributed nearly equally among them.

[0144] The principle of phase shifting technique is to generate a multi-level output PWM waveform using an incrementally shifted two-level waveform. Therefore, an N-level PWM waveform is created by summing N-1 two-level PWM waveforms. These two-level waveforms are obtained by summing a reference waveform with a triangular carrier wave 1400, 1410 ( Fig.14A , 14B ) is generated by comparison. Fig.14AA 9-level example 1400 is shown in FIG. 1. The carrier increment is offset by 360° / (9-1)=45° and compared with 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 interconnected ConSource modules, each ConSource module has a converter V1, a 0° signal is used for S3, and a 180° signal is used for S6 of the first ConSource module, a 45° signal is used for S3, and a 225° signal is used for S6 of the second ConSource module, and so on. Note that in all converters V1, 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 1430 resulting from the superposition of output voltages from four modules is depicted.

[0145] Fig.15 This one-dimensional array 1500 embodiment of the system 100 shown in makes it possible to obtain a high voltage of any shape with very low total harmonic distortion between the first and second terminals out1 and out2 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.

[0146] Fig.16 An exemplary 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 a number N of interconnected ConSource V1 / V2 / V3 modules 108-1, 108-2, ... 108-N. The configuration and output principle of the DC or AC voltage generation of each of the two one-dimensional arrays 1500 forming the two-dimensional array 1600 are described above with reference to Fig.15 The second port 2 of each of the Nth ConSource V1 / V2 / V3 modules in the Nth row or the 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.

[0147] This two-dimensional array of 2N interconnected 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, the load can be connected between the first and second output terminals Out1 and Out2, and the common terminal Out3 can be connected to the neutral point of the load.

[0148] 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.

[0149] Fig.16 This two-dimensional array embodiment of the system 100 shown in enables a two-phase system with a high voltage with 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 (MOSFETs, JFETs, IGBTs, 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).

[0150] 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 interconnected ConSource modules 108-1, 108-2, ... 108-N according to the present disclosure is shown. Fig.15 The configuration and output principle of DC or AC voltage generation for each of two one-dimensional arrays 1500 having a number N and N+1 interconnected ConSource modules forming the two-dimensional arrays is described. 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.

[0151] This two-dimensional array of 2N+1 interconnected 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.

[0152] Fig.18 An exemplary embodiment of a first version of a ConSource package according to the present disclosure is shown, which includes a plurality of ConSource V1 / V2 / V3 modules 108-1, 108-2, ... 108-N interconnected in a three-dimensional array 1800. 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. Fig.15 The configuration and output principle 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 are described. The second ports 2 of the Nth ConSource V1 / V2 / V3 modules in the Nth row or the last row of each of the three one-dimensional arrays are 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.

[0153] This three-dimensional array 1800 of 3N interconnected 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.

[0154] 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 one-dimensional array with the same number of N rows.

[0155] Fig.19 This 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 modules 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 phases. The system can also be connected to a three-phase load that is powered by energy source elements such as batteries, ultracapacitors, fuel cell units, etc.

[0156] Fig.19 An example embodiment of a second version of a ConSource package including a plurality of ConSource modules 108 interconnected in a three-dimensional array 1900 according to the present disclosure is shown.

[0157] 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.15The DC or AC voltage generation configuration and output principle of each of three one-dimensional arrays having a number N of interconnected ConSource V1 / V2 / V3 modules forming the three-dimensional arrays are described. The second port 2 of the first ConSource V1 / V2 / V3 module 108-1 is connected to the first port 1 of the ConSource V1 / V2 / V3 module 108-2 ("second ConSource V1 / V2 / V3 module") in the second row of the three one-dimensional arrays. The second port 2 of the second ConSource V1 / V2 / V3 module is connected to the first port 1 (not shown) of the ConSource V1 / V2 / V3 module in the third row of the three one-dimensional arrays, and so on further down to a number M rows of ConSource V1 / V2 / V3 modules in the same order, where M is 2 or greater.

[0158] 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.

[0159] 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.

[0160] This three-dimensional array of interconnected 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 .

[0161] 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.

[0162] Fig. 20 1 shows an example embodiment of a third version of a ConSource package according to the present disclosure including a plurality of ConSource modules interconnected by a three-dimensional array 2000. 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, which form the ConSource package based on the three-dimensional array 2000. Fig.15 The configuration and output principle of DC or AC voltage generation for each of three one-dimensional arrays having a number N of interconnected ConSource V1 / V2 / V3 modules 108-1, 108-2, ... 108-N forming the three-dimensional array are described. 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 108C 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 108C 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 108C 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 the N+1th row are interconnected, as shown in FIG. Fig. 20 as shown in .

[0163] This three-dimensional array of interconnected 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.

[0164] In addition to about Fig.18 In addition to the advantages mentioned, Fig. 20 This three-phase (three-dimensional array) configuration embodiment of the system 100 shown in FIG. 1—with two additional interconnected ConSource V3 modules 108 -C—enables efficient and rapid energy exchange (phase balancing) between all ConSource modules of the system and the phases of the grid or load.

[0165] Fig.21 An example embodiment of a fourth version of a ConSource package according to the present disclosure is shown that includes a plurality of ConSource modules interconnected in a multi-dimensional array 2100 (including K one-dimensional arrays 1500), where K is 3 or greater as an example, and is illustrated in an example orientation with multiple rows and K columns for purposes of presentation and reference only. 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-numbered one-dimensional arrays includes an M+N+1th additional ConSource V3 module 108C having first, second, third, and fourth ports.

[0166] 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 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 ConSource V1 / V2 / V3 module in the first row is connected to the first port 1 (not shown) of the ConSource V1 / 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.

[0167] 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.

[0168] The first port 1 of all the first to K-th 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 M-th row. The second port 2 of all the first to K-th 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 K-th 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.

[0169] 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.

[0170] This multi-dimensional array of interconnected 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.

[0171] 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 fast 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.

[0172] 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 are presented in and are further connected to any type of three-phase motor 2200.

[0173] Fig. 22 The three-dimensional array 1800 (three-phase motor drive system) embodiment of the system 100 shown in makes it possible to use low and / or medium voltage rated energy source elements and switch components (MOSFETs, JFETs, IGBTs, etc.) 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 motor phases A, B and C. Such a system does not require bulky passive filters as in the case of a 2-level inverter and has a high dynamic response.

[0174] 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 108 allows for a reduction in the total number of ConSource modules in the array to obtain a desired output motor voltage.

[0175] Fig.24 An example embodiment of a third version of a ConSource package connected to any type of three-phase motor 2200 is shown. 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 108C 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 1408. The first auxiliary load 1 and the second auxiliary load 2410 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.

[0176] In addition to about Fig.21 In addition to the advantages mentioned, Fig.24This 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-C - 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 above-mentioned system is delivered by the entire array of ConSource modules.

[0177] 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. Fig. 20 , wherein the third and fourth output ports 3 and 4 of the two additional ConSource V3 modules 108-C 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 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.

[0178] In addition to about Fig. 22 In addition to the advantages mentioned, Fig.25 This three-phase motor drive embodiment of the system 100 (three-dimensional array) shown in FIG. 1 - with two additional interconnected ConSource V3 modules 108-C - 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 ConSource V3 modules 108-C 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.

[0179] Fig.26An example embodiment 2600 of a fifth version of a ConSource package connected to any type of six-phase motor 2650 is shown. The ConSource package is 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 108C in the N+1th row are connected together and connected to the second auxiliary load 410, and the fifth and sixth ports 5 and 6 of the three additional ConSource V3 modules 108C in the N+1th row are 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 respectively represent, for example but not limited to, an on-board network system and an air conditioning power supply system of an electric vehicle.

[0180] 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-C - 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.

[0181] Fig. 27 An example embodiment 2700 of a sixth version of a ConSource package according to the present disclosure comprising a plurality of ConSource modules interconnected in a three-dimensional array, the plurality of ConSource modules being connected to two three-phase motors 2200, 2200' and an auxiliary load is shown. The first, second and third output terminals A, B and C of the first motor 12200 are connected to the ConSource package at the first port 1 of the ConSource V1 / V2 / V3 module 108-1 of the first row of the ConSource package. The second port 2 of the ConSource V1 / V2 / V3 module of the Nth row of all three array columns of the ConSource package is connected to the first port 1 of three corresponding ConSource V3 modules 108C of the N+1th row, as shown in FIG. Fig. 27. The second port 2 of all three ConSource V3 modules 108C in row N+1 is connected to the second port 2 of the ConSource V1 / V2 / V3 module in row N+2. The first port 1 of the ConSource V1 / V2 / V3 module in row N+2 is connected to the second port 2 of the ConSource V1 / V2 / V3 module in row N+3, and so on in the same order further down to the last row or row M of the ConSource package, as shown in FIG. Fig. 27 The first, second and third output terminals A', B' and C' of the second motor 22200' are connected to the ConSource package at the first port 1 of the ConSource V1 / V2 / V3 module of the Mth row of the ConSource package.

[0182] The third and fourth ports 3 and 4 of the three additional ConSource V3 modules 108C in the N+1th row are connected together and connected to the second auxiliary load 410. The fifth and sixth ports 5 and 6 of the three additional ConSource V3 modules 108C in the N+1th row are 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 respectively represent, for example but not limited to, an onboard network system and an air conditioning power supply system of an electric vehicle.

[0183] This three-dimensional array embodiment of system 100 has Fig. 27 The three additional interconnected ConSource V3 modules shown in , provide independent voltage and frequency regulation (control) for two independent motors (dual motor drive system), and enable 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 108C 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 onboard network and HVAC power lines. In this case, no additional low voltage battery is required; the energy for the above system is provided by the entire ConSource module array.

[0184] Fig.28 An example embodiment 2800 of a seventh version of a ConSource package according to the present disclosure is shown including a plurality of ConSource modules 108 interconnected in a three-dimensional array connected to a three-phase open winding motor 2850 and auxiliary loads 408 , 410 .

[0185] 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.28 As shown in FIG. 1 , the second port 2 of the ConSource V1 / V2 / V3 module 108-N of the Nth row of all three array columns is connected to the first, second and third input 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 108C 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 108C 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 108C in the M+1th row.

[0186] 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.

[0187] In addition to about Fig. 22 In addition to the advantages mentioned, Fig.28This 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 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 above-mentioned system is delivered by the entire array of ConSource modules.

[0188] Fig.29 An example embodiment of an eighth version of a ConSource package according to the present disclosure comprising a plurality of ConSource modules interconnected in a three-dimensional array 2900 connected to two three-phase open winding motors 2850 , 2850 ′ and auxiliary loads 408 , 410 is shown.

[0189] 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 108-1 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 108-2 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 input terminals A, B, C of the first open winding motor 2850, as shown in FIG. Fig.29 . The first, second and third output terminals A', B', C' 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 108-(N+2) in the N+2th row of all three array columns, and so on further down to the Mth row in the same order.

[0190] 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 packet is connected to the first port 1 of the three corresponding ConSource V3 modules 108C in the M+1th row, such as Fig.29 . The second port 2 of all three ConSource V3 modules 108C 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 A, B, C of the second open winding motor 2850', as shown in FIG. Fig.29 as shown in .

[0191] The first, second and third output terminals A', B', C' 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+1st row of all three array columns. The first port 1 of the ConSource V1 / V2 / V3 module in the K+1st 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+2nd 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.

[0192] 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.

[0193] have Fig.29This 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.

[0194] Example Embodiment of Module Control

[0195] Steering Figure 30-40B , shows an example system and method for facilitating a control system 100 to provide state of charge (SOC) and temperature balance between ConSource modules in different system configurations. Fig.29 The interconnect architecture of the example embodiment shown in enables control of power sharing between ConSource modules. Such control enables SOC balance of the Energy Sources of the ConSource modules to be maintained during cycling and quiescence, 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 Energy Source temperatures 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.

[0196] 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 detects a peak value Vpk of a reference voltage Vr. 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 uses the peak voltage Vpk together with ConSource state information (e.g., SOCi, Ti, Qi, Vi, etc.) to generate a modulation index Mi for each module. The intra-phase balance controller may be implemented as a centralized controller as part of an MCD in the form of hardware, software, or a combination thereof, or may be distributed in part or in whole in an LCD as described herein.

[0197] In the case of single-phase AC or DC, as part of the MCD, the intra-phase balancing controller 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. The balancing controller 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 can be sent continuously, and the modulation index can be sent at regular intervals, such as once per Vrn cycle. The LCD can modulate or scale the normalized reference voltage Vrn by the received modulation index. (In some examples, the modulation index can be a number between zero and one (including zero and one).) According to the reference Figures 14A-14D The pulse width modulation technique described above, the modulated or scaled Vrn can be used as Vref (or -Vref). In this way, the modulation index can be used to control the PWM switching signal generated by the LCD, and thus adjust the operation of each ConSource module. For example, a ConSource module controlled to maintain normal or full operation can receive a modulation index of one, while a ConSource module controlled to operate less than normal or fully can receive a modulation index less than one. A ConSource module controlled to stop power output can 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 can be used to achieve similar functionality.

[0198] The intra-phase balancing controller may 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, temperature, capacity, and / or voltage 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. Different combinations of modulation indices may be used, but the total generated voltage should remain the same, such as Fig.31 as shown in the phasor diagram 3100; the state of charge (SOC) of the battery modules of the ConSource remain balanced, or if they are unbalanced, converge to a balanced condition; and when the temperature of at least one battery module of a ConSource exceeds a certain threshold, the temperature of the battery modules of the ConSource are balanced.

[0199] Since state of charge and temperature balancing may not be possible at the same time, both can be applied in combination and one can be given priority depending on the requirements of the application.

[0200] like Fig.32As shown in , the three-phase balancing controller 3200 may include an inter-phase balancing controller 3210 and three intra-phase balancing controllers 3220-1, 3220-2, and 3220-3. The task of the intra-phase balancing controller is to balance the various aspects of the ConSource modules within each one-dimensional array (particularly and as an example within one phase). The inter-phase balancing controller can balance the various aspects of the ConSource modules throughout the multi-dimensional array (particularly and as an example between the three phases). In the Y-type connection of the phases, this can be achieved by injecting a common mode (neutral point offset) into the phase or through a common module or through both. The intra-phase balancing controllers 3220-1, 3220-2, 3220-3 and the inter-phase balancing controller 3210 can be implemented as a centralized controller as part of the MCD using hardware, software, or a combination thereof, or can be partially or fully distributed in the LCD described herein.

[0201] The reference signal input to the system can be V rA 、V rB 、V rC or any combination of two of these signals, or any other transform that can recreate these signals, such as the Clarke transform (i.e. V rα 、V rβ ).

[0202] In a Y-connected three-phase structure without a common module between phases (for example, see Fig.18 and 22 In the system 100 described above, intra-phase balance can be achieved by controlling the modulation index of the modules in each phase 3300, 3300', 3300", such as Fig.33A By adding some common mode to the phase reference, the neutral point “N” can be Fig.33B is shown as offset by 3310. This provides control of the share of each phase to establish the three-phase voltage. For example, in Fig.33B , 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, and less than the total energy available in the modules of phase B, for SOC balance, the neutral point should be shifted as shown to reduce the contribution of phase A and phase C, respectively, and increase the contribution of phase B.

[0203] In the Y-type connected three-phase structure, there are common modules between phases 3400, 3400', which are ConSourceV3 modules (for example, see system 100, Fig. 20 and Fig.24 ), intra-phase balance can be achieved by controlling the modulation index of the modules in each phase. Inter-phase balance can be achieved by controlling only the contribution of (one or more) common modules to each phase, such as Fig.34Aas shown in ; neutral point offset; or as Fig.34B Both shown in .

[0204] In the four-phase system 3500, 3500', as with respect to the one without common module (ConSource V3) Fig.35A and with public modules (ConSource V3) Fig.35B As described, intra-phase balance can be achieved by controlling the modulation index of the modules within each phase. Inter-phase balance can be achieved by neutral point offset and / or by controlling the contribution of the common modules to each phase where applicable.

[0205] In the five-phase system 3600, 3600', as for the case where there is no common module (ConSource V3) Fig.36A and with a common module (ConSource V3) Fig.36B As described above, intra-phase balance can be achieved by controlling the modulation index of the modules in each phase. Inter-phase balance can be achieved by neutral point offset and / or by controlling the contribution of the common modules to each phase where applicable.

[0206] In the six-phase system 3700, 3700', as with respect to the one without common module (ConSource V3) Fig.37A and with a common module (ConSource V3) Fig.37B As described, (modification of system 100, Fig.26 ), intra-phase balance can be achieved by controlling the modulation index of the modules within each phase. Inter-phase balance can be achieved by neutral point offset and / or by controlling the contribution of the common modules to each phase where applicable.

[0207] In reference Fig. 27 In the described system 100, two systems 3810, 3820 of a three-phase structure that can operate at different voltages and frequencies are considered. Intra-phase balancing can be achieved by controlling the modulation index of the modules within each phase. Inter-phase balancing within each system and between the two systems can be achieved by controlling the voltage contribution of the common module (ConSource V3) to each phase, such as Fig.38A As shown in Fig.38B As shown in , the phase balance within each system 3810, 3820 can be further improved by neutral point offset.

[0208] In reference Fig.28 In the depicted system 100 , two systems of three-phase configuration are considered that operate at similar frequencies but may have different voltages.

[0209] exist Fig.39AIn the embodiment, since the complementary phases in the two systems 3900, 3900' work in pairs to generate voltage across each motor winding, the modules in each phase can be considered for intra-phase balancing. For example, in order to establish a certain voltage between A and A', all modules in phase A and phase A' should contribute their status information accordingly.

[0210] The phase balance or in this case the balance between the phases can be obtained by Fig.39A and / or by using the common modules shown in Fig.39B This is achieved by the neutral point offset shown in .

[0211] In reference Fig.29 In the described system 100, two ACi battery pack systems are connected through a common module and used to drive two motors. Therefore, system 1 and system 2 can operate at different voltages and frequencies, while in each system, the two parts operate at equal frequencies but can have different voltages.

[0212] Without neutral point offset, the relative (e.g., A1 and A′1) modules of each system 4010, 4020, 4030 can be realized. Fig.40A The interphase balance within and between the two systems can be achieved by controlling the voltage contribution of the common module to each phase in the two systems.

[0213] Can increase as Fig.40B The neutral point shown in is offset to improve the balance between phases and systems 4010, 4020, 4030.

[0214] 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.41 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 4202 for the converter V1 or V2 206, 308, the energy buffer 204, and the energy source 1202 (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.

[0215] Fig.42is 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 4203 that houses the LCD of the module 108 as well as the converter V1 or V2 and energy buffer. The energy source 1202 (and optional energy source 2304, if present) are provided in a separate housing 4204. The housings 4203 and 4204 may be physically coupled or connected together prior to installation into the system 100, or may be separate, unconnected entities.

[0216] In any and all embodiments described herein, various circuit components may be integrated on one or more substrates to reduce the form factor. Figure 41-42 As described, the LCD may be part of a ConSource module. Fig.43A 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 4302, which may be a single printed circuit board (PCB). These components may be electrically coupled to the substrate 4302 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 4302.

[0217] Fig.43B is a schematic diagram 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 4304, which may be a single printed circuit board (PCB). These components may be electrically coupled to substrate 4304 and to each other to permit signal or data exchange between them. LCD 114 is mounted or secured to a different substrate 4306, which may also be a single PCB. Other passive or active components may be mounted or secured to substrates 4304 and 4306 alike. Communication between components on the LCD and substrate 4304 may be performed via one or more buses, wires, or optical fibers.

[0218] 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.

[0219] In Figures 1-8F, 11, 13, 15-30, 32 and Figures 1A-1C and Figure 41-43B In the 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) . 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, one 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 connected or indirectly coupled or connected.

[0220] 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.

[0221] 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.

[0222] Those of ordinary skill in the art will appreciate that the term "module" as used herein refers to a device 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.

[0223] 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).

[0224] The term "output" as used herein is broad and does not exclude operating in a bidirectional manner as both output and input. Similarly, the term "input" as used herein is broad and does not exclude operating in a bidirectional manner as both output and input.

[0225] The terms "terminal" and "port" as used herein are broad and may be unidirectional or bidirectional, may be input or output, and do not require a specific physical or mechanical structure such as a female or male configuration.

[0226] 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.

[0227] 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.

[0228] 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.

[0229] 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.

[0230] 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.

[0231] 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.

[0232] 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.

[0233] 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.

[0234] 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.

[0235] 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.

[0236] 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.

[0237] 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.

[0238] 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.

[0239] 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.

[0240] 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.

[0241] 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.

[0242] 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 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.

[0243] 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.

[0244] In many of the aforementioned embodiments, the module-based energy system further includes a local control device communicatively coupled to the converter-source module.

[0245] 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.

[0246] 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.

[0247] In many of the aforementioned embodiments, the local control device is configured to generate the switching signals for the converter using pulse width modulation.

[0248] 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.

[0249] 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.

[0250] 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.

[0251] In many of the aforementioned embodiments, the local control device is powered only by the first energy source.

[0252] In many of the aforementioned embodiments, the local control device is powered by an energy source that is different from the first energy source.

[0253] 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 using current from the second energy source.

[0254] 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.

[0255] 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.

[0256] 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.

[0257] 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.

[0258] In many of the aforementioned embodiments, the module-based energy system further includes a master control device communicatively coupled to the local control device.

[0259] 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 for 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.

[0260] In many of the aforementioned embodiments, the module-based energy system is configured for operation in a mobile entity.

[0261] 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.

[0262] In many of the aforementioned embodiments, the module-based energy system is configured to operate as a stationary energy system.

[0263] 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.

[0264] In many of the aforementioned embodiments, the module-based energy system is configured as a battery pack for an electric vehicle.

[0265] 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.

[0266] 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.

[0267] 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.

[0268] 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.

[0269] 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.

[0270] 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.

[0271] 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.

[0272] In many embodiments, a module-based energy system comprises M arrays of converter-source modules, wherein M is 2 or greater, wherein each of the M arrays comprises N converter-source modules, wherein N is 2 or greater, wherein each of the N converter-source modules is connected in series in each of the M arrays, wherein each of the N converter-source modules is configured according to any of the aforementioned embodiments, wherein each of the M arrays comprises individual output terminals of a first converter-source module, and wherein the Nth converter-source module in each of the M arrays is connected to a common output terminal.

[0273] 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 line 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.

[0274] In many embodiments, a module-based energy system includes first and second arrays of converter-source modules, wherein the first array includes N converter-source modules and the second array includes N-1 converter-source modules, wherein N is 2 or greater, wherein each of the N converter-source modules is connected in series in the first array and each of the N-1 converter-source modules is connected in series in the second array, wherein each of the N converter-source modules and the N-1 converter-source modules includes an energy source, an energy buffer, and a converter, wherein each of the first and second arrays includes individual output terminals of the first converter-source module, and wherein the Nth converter-source module in each of the first array and the N-1th converter-source module in the second array are connected to a common output terminal.

[0275] 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 and the N-1 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 individual output terminals of the first and second arrays. In many of these embodiments, the common output terminal is coupled to the neutral line 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 load is one of a DC load or a single-phase AC load.

[0276] In many embodiments, a module-based energy system includes first, second, and third arrays of converter-source modules, wherein each of the first, second, and third arrays includes N+M converter-source modules, wherein N is equal to or greater than 2 and M is equal to or greater than 2, wherein each of the N+M converter-source modules includes an energy source, an energy buffer, and a converter, wherein each of the N+M converter-source modules includes a first and a second port, wherein each of the first, second, and third arrays includes an individual output terminal coupled to a first port of a first converter-source module, wherein the first converter of each of the first, second, and third arrays includes an individual output terminal coupled to a first port of a first converter-source module, and wherein the first converter of each of the first, second, and third arrays includes an individual output terminal coupled to a first port of a first converter-source module. The first, second and third arrays are connected in series from an Nth to an Nth converter-source module, wherein the Nth to an N+Mth converter-source module of each of the first, second and third arrays are connected in series, wherein a second port of the N+Mth converter-source module of the first array is connected to a first port of the Nth converter-source module of the second array, wherein a second port of the N+Mth converter-source module of the second array is connected to a first port of the Nth converter-source module of the third array, and wherein a second port of the N+Mth converter-source module of the third array is connected to a first port of the Nth converter-source module of the first array.

[0277] In many of these embodiments, the series connection of the first converter-source module to the Nth converter-source module of each of the first, second, and third arrays includes the first port of the second converter-source module to the Nth converter-source module of each of the first, second, and third arrays connected to the second port of the previous converter-source module in the series of converter-source modules including the first converter-source module to the N-1th converter-source module. In many of these embodiments, the series connection of the Nth converter-source module to the N+Mth converter-source module of each of the first, second, and third arrays includes the first port of the N+1th converter-source module to the N+Mth converter-source module of each of the first, second, and third arrays connected to the second port of the previous converter-source module in the series of converter-source modules including the Nth converter-source module to the N+(M-1)th converter-source module. 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+M 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 individual output terminals of the first, second, and third arrays. In many of these embodiments, the load is one of a DC or a single-phase AC load or a three-phase AC load.

[0278] In many embodiments, a module-based energy system includes first, second, and third arrays of converter-source modules, wherein each of the first and third arrays includes N+1 converter-source modules and the second array includes N converter-source modules, wherein N is 2 or greater, wherein each of the first to Nth converter-source modules includes an energy source, an energy buffer, and a converter, wherein the N+1th converter-source module of each of the first and third arrays includes an energy source, an energy buffer, a converter, and is configured to be connected to one or more auxiliary loads, wherein each of the first to Nth converter-source modules includes a first and a second port, wherein the N+1th converter-source module of each of the first and third arrays includes a first, a second, a third, and a fourth port, wherein the first, second, and third input The output terminals are respectively coupled to the first ports of the first converter-source modules of the first, second and third arrays, respectively, wherein the first converter-source modules to the Nth converter-source modules of each of the first, second and third arrays are connected in series, wherein the second port of the Nth converter-source module of each of the first and third arrays is respectively connected to the first port of the N+1th converter-source module of each of the first and third arrays, respectively, wherein the second port of the N+1th converter-source module of the first array is connected to the second port of the Nth converter-source module of the second array, wherein the second port of the N+1th converter-source module of the third array is connected to the fourth output terminal, and wherein the third and fourth ports of the N+1th converter-source module of the first array are respectively connected to the third and fourth ports of the N+1th converter-source module of the third array.

[0279] In many of these embodiments, the second port of the second converter-source module of the third array is connected to the first port of the first converter-source module of the first array. In many of these embodiments, the N+1 converter-source module of each of the first and third arrays further includes a fifth and a sixth port, and wherein the one or more auxiliary loads of the N+1 converter-source modules of the first and third arrays include a first auxiliary load connected to the fifth and sixth ports of the N+1 converter-source module of each of the first and third arrays and a second auxiliary load connected to the third and fourth ports of the N+1 converter-source module of each of the first and third arrays. 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+1 converter-source modules of the first and third arrays and the N converter-source modules of the second array. 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 plurality of local control devices, each of which is communicatively coupled to one or more of the N+1 converter-source modules of the first and third arrays and the N converter-source modules of the second array. 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, second, and third output terminals of the first, second, and third arrays. In many of these embodiments, the load is one of a DC or single-phase AC load or a three-phase AC load. In many of these embodiments, the module-based energy system further includes a load connected between the first, second, and third output terminals of the first, second, and third arrays. In many of these embodiments, the module-based energy system further includes a load connected between the first, second, and third output terminals of the first, second, and third arrays. In many of these embodiments, the module-based energy system further includes a load connected between the first, second, and third output terminals of the first, second, and third arrays. In many of these embodiments, the load is one of a DC or single-phase AC load or a three-phase AC load.

[0280] In many embodiments, a module-based energy system includes first, second, third, fourth, fifth, and sixth arrays of converter-source modules, wherein each of the first, third, and fifth arrays includes N+1 converter-source modules, and each of the second, fourth, and sixth arrays includes N converter-source modules, where N is 2 or greater, wherein each of the N converter-source modules and the N+1 converter-source modules includes an energy source, an energy buffer, and a converter, wherein each of the first converter-source module to the Nth converter-source module includes a first and a second port, wherein the N+1th converter-source module of each of the first, third, and fifth arrays includes a first, second, third, fourth, fifth, and sixth port, and wherein a first auxiliary load is connected to the fifth and sixth ports of the N+1th converter-source module of each of the first, third, and fifth arrays, and a second auxiliary load is connected to the third and the sixth ports of the N+1th converter-source module of each of the first, third, and fifth arrays. four ports, wherein first, second, third, fourth, fifth and sixth output terminals are respectively coupled to first ports of first converter-source modules of first, second, third, fourth, fifth and sixth arrays, respectively, wherein the first to Nth converter-source modules of each of the first, second, third, fourth, fifth and sixth arrays are connected in series, wherein the second port of the Nth converter-source module of each of the first, third and fifth arrays is respectively connected to the first port of the N+1th converter-source module of each of the first, third and fifth arrays, respectively, wherein the second port of the N+1th converter-source module of the first array is connected to the second port of the Nth converter-source module of the second array, wherein the second port of the N+1th converter-source module of the third array is connected to the second port of the Nth converter-source module of the fourth array, and wherein the second port of the N+1th converter-source module of the fifth array is connected to the second port of the Nth converter-source module of the sixth array.

[0281] 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+1 converter-source modules of the first, third, and fifth arrays and one or more of the N converter-source modules of the second, fourth, and sixth 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 energy system further includes a load connected between the first, second, third, fourth, fifth, and sixth output terminals of the first, second, third, fourth, fifth, and sixth arrays. In many of these embodiments, the load is a six-phase AC load.

[0282] In many embodiments, a module-based energy system includes K one-dimensional arrays of interconnected converter-source modules, wherein K is 3 or greater and is an odd number, each of the first and K-th arrays and each odd-numbered array therebetween includes N+M+1 converter-source modules, and each of each even-numbered array between the second array and the K-1-th array includes N+M converter-source modules, and wherein N and M are 2 or greater, wherein each of the first to N+M-th converter-source modules includes an energy source, an energy buffer, and a converter, wherein the N+M+1-th converter-source module of each of the first, K-th, and other odd-numbered arrays includes an energy source, an energy buffer, a converter, and is configured to be connected to one or more auxiliary loads, wherein each of the first to N+M-th converter-source modules of each of the K arrays includes a first and a second port, wherein the N+M+1-th converter-source module of each of the first, K-th, and other odd-numbered arrays includes an energy source, an energy buffer, a converter, and is configured to be connected to one or more auxiliary loads, wherein each of the first to N+M-th converter-source modules of each of the K arrays includes a first and a second port, wherein the N+M+1-th converter-source module of each of the first, K-th, and other odd-numbered arrays includes an energy source, an energy buffer, a converter, and is configured to be connected to one or more auxiliary loads. The converter-source module comprises first, second, third and fourth ports, wherein K individual output terminals are respectively coupled to the first port of the first converter-source module of each of the K arrays, wherein the first converter-source module of each of the K arrays is connected in series to the N+M-th converter-source module, wherein the second port of the N+M-th converter-source module of each of the first, K-th and other odd-numbered arrays is respectively connected to the first port of the N+M+1-th converter-source module of each of the first, K-th and other odd-numbered arrays, wherein the second port of the N+M-th converter-source module of the second, K-1-th and other even-numbered arrays therebetween is connected to the second port of the N+M+1-th converter-source module of the previous array of the K arrays, wherein the second port of the N+M+1-th converter-source module of the K-th array is connected to the K+1-th output terminal, and wherein the third and fourth ports of the N+M+1-th converter-source modules of the first, M-th and other odd-numbered arrays are respectively connected to each other.

[0283] In many of these embodiments, the second port of the Nth converter-source module of the Kth array is connected to the first port of the first converter-source module of the first array. In many of these embodiments, the first port of the first converter-source module in the second to Kth arrays is connected to the second port of the Nth converter-source module of the previous array. 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+M+1 converter-source modules of the first, Kth and other odd arrays and each of the N+M converter-source modules of the second, M-1st and other even arrays. In many of these embodiments, the module-based energy system further includes a master controller that communicates with the plurality of local control devices. In many of these embodiments, the module-based energy system further includes a multi-phase load connected between the first to Kth output terminals of the K arrays. In many of these embodiments, the module-based energy system further includes a multi-phase load connected between the first to Kth output terminals of the K arrays. In many of these embodiments, the module-based energy system further includes a load connected between the first, second and third output terminals of the M arrays. In many of these embodiments, the module-based energy system further comprises a load connected between the first, second and third output terminals of the M arrays. In many of these embodiments, the load is one of a DC or a single-phase AC load or a three-phase AC load.

[0284] In many embodiments, a module-based energy system includes first, second, third, fourth, fifth, and sixth arrays of N converter-source modules, wherein N is 2 or greater, wherein each of the N converter-source modules includes an energy source, an energy buffer, and a converter, and a first and a second port, wherein a first, second, third, fourth, fifth, and sixth output terminal are respectively coupled to a first port of a first converter-source module of the first, second, third, fourth, fifth, and sixth arrays, wherein a first three-phase AC load is connected between the first, second, and third output terminals of the first, second, and third arrays, wherein a second three-phase AC load is connected between the fourth, fifth, and sixth output terminals of the fourth, fifth, and sixth arrays, wherein the N converter-source modules of each of the first, second, third, fourth, fifth, and sixth arrays are connected in series. A series connection is provided, wherein the second port of the Nth converter-source module of the first array is connected to the second port of the Nth converter-source module of the fourth array, wherein the second port of the Nth converter-source module of the second array is connected to the second port of the Nth converter-source module of the fifth array, wherein the second port of the Nth converter-source module of the third array is connected to the second port of the Nth converter-source module of the sixth array, wherein the Nth converter-source module of each of the first, second and third arrays further includes a third, fourth, fifth and sixth port, and wherein a first auxiliary load is connected to the fifth and sixth ports of the Nth converter-source module of each of the first, second and third arrays, and a second auxiliary load is connected to the third and fourth ports of the Nth converter-source module of each of the first, second and third arrays.

[0285] 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, and sixth 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.

[0286] In many embodiments, a module-based energy system includes first, second, third, and fifth arrays of N converter-source modules and fourth and sixth arrays of N+1 converter-source modules, where N is 2 or greater, wherein each of the N converter-source modules and the N+1 converter-source modules includes an energy source, an energy buffer, and a converter, and a first and second port, wherein a first, second, third, fourth, fifth, and sixth output terminal are coupled to a first port of a first converter-source module of the first, second, third, fourth, fifth, and sixth arrays, respectively, wherein a six-phase AC load is connected between the first, second, third, fourth, fifth, and sixth output terminals of the first, second, third, fourth, fifth, and sixth arrays, respectively. The N converter-source modules of one and the N+1th converter-source module of each of the fourth and sixth arrays are connected in series, wherein the second port of the N+1th converter-source module of the fourth array is connected to the second port of the Nth converter-source module of the fifth array, wherein the second port of the N+1th converter-source module of the sixth array is connected to the fourth output terminal, wherein the N+1th converter-source module of each of the fourth and sixth arrays further includes a third, fourth, fifth and sixth ports, and wherein a first auxiliary load is connected to the fifth and sixth ports of the Nth converter-source module of each of the first, second and third arrays, and a second auxiliary load is connected to the third and fourth ports of the Nth converter-source module of each of the first, third and third arrays.

[0287] In many of these embodiments, the module-based energy system further includes 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, and third arrays and the N+1 converter-source modules of the fourth and sixth 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.

[0288] In many embodiments, a module-based energy system comprises first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh and twelfth arrays of N converter-source modules, wherein N is 2 or greater, wherein each of the N converter-source modules comprises an energy source, an energy buffer and a converter, and a first and a second port, wherein a first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh and twelfth output terminal is coupled to a first port of a first converter-source module of the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh and twelfth array, respectively, wherein a first six-phase AC load is connected between the first, second, third, seventh, eighth and ninth output terminals of the first, second, third, seventh, eighth and ninth arrays, and wherein a second three-phase AC load is connected between the fourth, fifth, sixth, tenth, eleventh and twelfth output terminals of the fourth, fifth, sixth, tenth, eleventh and twelfth arrays. wherein the N converter-source modules of each of the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh and twelfth arrays are connected in series, wherein the second port of the Nth converter-source module of the first array is connected to the second port of the Nth converter-source module of the fourth array, wherein the second port of the Nth converter-source module of the second array is connected to the second port of the Nth converter-source module of the fifth array, wherein the second port of the Nth converter-source module of the third array is connected to the second port of the Nth converter-source module of the sixth array, wherein the Nth converter-source module of each of the first, second and third arrays further includes a third, fourth, fifth and sixth port, and wherein a first auxiliary load is connected to the fifth and sixth ports of the Nth converter-source module of each of the first, second and third arrays, and a second auxiliary load is connected to the third and fourth ports of the Nth converter-source module of each of the first, second and third arrays.

[0289] 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.

[0290] In many embodiments, a module-based energy system includes a plurality of interconnected 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.

[0291] In many of these embodiments, the converter-source module comprises a converter-source module according to many of the aforementioned embodiments.

[0292] 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 charge state, 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 charge state (SOC) of multiple interconnected 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 to 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.

[0293] 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.

[0294] 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.

[0295] 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.

[0296] 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 using the modulated reference waveform.

[0297] 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 source of multiple converter-source modules to 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 to a balanced condition. In many of these embodiments, multiple modulation indices Mi are generated to converge the capacity of multiple converter-source modules to a balanced condition. In many of these embodiments, multiple modulation indices Mi are generated to converge the voltage of multiple converter-source modules to a balanced condition. In many of these embodiments, multiple modulation indices Mi are generated to converge the current of multiple converter-source modules to a balanced condition. In many of these embodiments, multiple modulation indices Mi are generated to converge the temperature of multiple converter-source modules to a balanced condition. In many of these embodiments, multiple modulation indices Mi are generated to converge the temperature of multiple converter-source modules to 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.

[0298] 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 multidimensional array. In many of these embodiments, the intraphase balance controller is configured to adjust the contribution of a plurality of converter-source modules within a one-dimensional array of the multidimensional array. In many of these embodiments, the interphase balance controller is configured to control one or more of the contribution of a converter-source module common to each phase or a neutral point offset.

[0299] 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.

[0300] In many of the aforementioned embodiments, a plurality of converter-source modules are arranged in a multi-dimensional array.

[0301] In many of the aforementioned embodiments, a plurality of converter-source modules are arranged according to any of the many of the aforementioned embodiments.

[0302] 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.

[0303] 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.

[0304] In many of the aforementioned embodiments, the module-based energy system is configured as a battery pack for an electric vehicle.

[0305] In many embodiments, a module-based energy system comprises a plurality of interconnected 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.

[0306] 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 multidimensional array. In many of these embodiments, multiple converter-source modules are arranged according to many of the aforementioned embodiments.

[0307] 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.

[0308] 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 switch signals for multiple switches from a local control device.

[0309] In many embodiments, according to many of the aforementioned embodiments, the energy system comprises at least two converter-source modules.

[0310] In many of these embodiments, at least two converter-source modules are interconnected 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 the energy source, protects the energy buffer, and controls the converter.

[0311] In many embodiments, a module-based energy system includes a local control device and a converter-source module interconnected with 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.

[0312] In many of these embodiments, the storage element comprises a supercapacitor, a battery module comprising one or more interconnected 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 interconnected 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, the storage element including one of the following: an electrolytic and / or film capacitor, a supercapacitor, a battery module including one or more interconnected 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 interconnected battery cells, an electrolytic and / or film capacitor connected in parallel with a supercapacitor, and a battery module including one or more interconnected battery cells. In many of these embodiments, the converter includes six switches. In many of these embodiments, the converter-source module is configured to supply power to the first and second auxiliary loads.

[0313] 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.

[0314] 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.

[0315] 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.

[0316] 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.

[0317] 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.

[0318] 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.

[0319] In these embodiments, the control circuit may control the power contribution of each converter-source module in the plurality of converter-source modules.

[0320] In these embodiments, the control circuit may control the power contribution based on pulse width modulation or hysteresis techniques.

[0321] 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.

[0322] 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.

[0323] 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.

[0324] 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.

[0325] 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.

[0326] Any and all signals described herein can 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 through 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 on a link. The processing circuit may also be docked with the communication circuit to perform the reverse function necessary to receive 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.

[0327] 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.

[0328] 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.

[0329] 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.

[0330] 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 is 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 is 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 based on the persistence of the storage device or other aspects. 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 variants thereof.

[0331] 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.

[0332] As used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0333] 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: Converter-source module, including: The 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 A local control device is 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.

2. A module-based energy system comprising: Converter-source module, including: The 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 A local control device is communicatively coupled to the converter-source module, wherein the first energy source provides operating power to the local control device.

3. A module-based energy system comprising: Converter-source module, including: The 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 A local control device is 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. The system of claim 3 , wherein the fault signal indicates an actual fault or a potential fault.

5. A module-based energy system comprising: Converter-source module, including: The first energy source; an energy buffer coupled to the first energy source; 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 a local control device communicatively coupled to the converter-source module, The local control device, energy buffer and converter are implemented together on a single printed circuit board.

6. A module-based energy system comprising: Converter-source module, including: The first energy source; an energy buffer coupled to the first energy source; 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 a local control device communicatively coupled to the converter-source module, The local control device, the energy buffer and the converter are accommodated in a common housing that does not accommodate the first energy source.

7. A module-based energy system comprising: Converter-source module, including: The first energy source; an energy buffer coupled to the first energy source; 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 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 accommodated in a common housing which does not accommodate another converter-source module.

8. A module-based energy system comprising: Converter-source module, including: The first energy source; an energy buffer coupled to the first energy source; 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 a local control device communicatively coupled to the converter-source module, The local control device, the energy buffer and the converter are accommodated in a common housing that does not accommodate the first energy source.

9. A module-based energy system comprising: Converter-source module, including: The 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 comprises a plurality of switches configured to select an output voltage of the module, The energy buffer and the converter are implemented together on a single printed circuit board.

10. A module-based energy system comprising: Converter-source module, including: a first energy source comprising a fuel cell unit; an energy buffer coupled to the first energy source; A converter is coupled to a first energy source and an energy buffer, wherein the converter includes a plurality of switches configured to select an output voltage of the module.

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