Communication system and synchronization techniques for energy storage systems

Abstract

Exemplary embodiments of systems, apparatuses, and methods are provided herein for an energy system that includes an array of cascaded modules configured to output a voltage waveform and / or a current waveform to a load. Each module may include an energy source, switching circuitry, and a local control device. Each module may have an identifier. The energy system may include a master control device communicatively coupled to each local control device through a communication path. The master control device may be configured to send control information data elements to the local control device over the communication path. Each control information data element may include a normalized reference signal for each module in the array of cascaded modules, a single identifier selected from a set of identifiers including the identifier for each module in the array of cascaded modules, and a modulation index for the module having the single identifier.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 323,359, filed on March 24, 2022, which is incorporated herein by reference in its entirety for all purposes. Technical Field

[0003] The subject matter described in this document generally relates to communication systems for module-based energy systems, and systems, devices, and methods that facilitate connection and control of modules in module-based energy systems. Background Art

[0004] In electrical engineering, power engineering, and the power industry, power conversion is the conversion of electrical energy from one form to another (e.g., converting between AC and DC, adjusting voltage or frequency, or some combination of these). The proliferation of devices for generating, utilizing, and using electrical energy in various forms requires the development of high-capacity electrical energy storage systems, sometimes referred to as energy storage systems (ESS). These ESSs include ESSs for fixed applications (e.g., energy storage for buffering from the power grid) and mobile applications (e.g., electric vehicle battery packs). ESSs typically have power conversion capabilities placed at discrete interfaces between the entire ESS and some other power consumption or power generation entity (e.g., load or power grid). ESSs typically rely on a combination of many smaller electrochemical cells connected in a single series chain to receive and store the electrical energy from the power grid before outputting it to the load. The process of receiving and outputting electrical energy may involve some power conversion performed at a discrete interface between the ESS and the power grid or load. However, the performance of power conversion at this discrete interface is relatively non-dynamic, introduces losses, thereby reducing the efficiency of the ESS, and can be expensive. Furthermore, reliance on a single series chain of batteries significantly limits the capabilities of the ESS since the series chain can only output a single voltage, is susceptible to failure of any one of the series batteries, and has a limited useful life since each battery within the series chain degrades differently due to structural and chemical differences inherent in each battery.

[0005] For these and other reasons, there is a need for new systems, devices, and methods for storing electrical energy, outputting electrical energy, and performing electrical power conversion in an improved manner. Summary of the invention

[0006] Provided herein are exemplary embodiments of systems, devices, and methods for module-based energy systems that are widely relevant to many applications and include a communication interface that enables a master control device to send control information to local control devices of various modules. In general, the communication interface enables the master control device to communicate with local control devices of a cascaded module array through a communication path, and the cascaded module array is configured to output a voltage waveform and / or a current waveform to a load. For example, the module may selectively operate in a voltage source mode for outputting a voltage waveform or in a current source mode for outputting a current waveform. The communication interface may be a serial or parallel interface that provides unidirectional data communication from the master control device to the corresponding local control device of each cascaded module. The master control device, for example, periodically sends control information data elements such as packets to the local control devices so that the local control devices can adjust the characteristics of their corresponding output power.

[0007] Each control information data element may include a single reference signal for all modules in an array of cascaded modules and a modulation index for one of the modules in the array. In order to enable a cascaded module to determine whether a modulation index is for the cascaded module, each control information data element may also include an identifier of the cascaded module to which the modulation index applies. The master control device may cycle through the cascaded modules in sequence so that the local control device for each cascaded module receives an updated modulation index in one of the control information elements sent in sequence. This may reduce the length of the control information data element and increase the sampling of the reference signal at each module. For example, this enables the master control device to send the reference signal more frequently per the same time period. This more frequent sampling improves the voltage and / or current regulation accuracy and reduces the time response of the reference signal change.

[0008] Each control information data element may also include one or more safety signals. For example, each control information data element may include cyclic redundancy check (CRC) information for error detection and data correction.

[0009] The local control device of each cascade module can use its most recently received modulation index to scale the most recently received reference signal of the most recently received control information data element, and use the scaled reference signal to control the switch circuit system of the cascade module. The local control device can use the scaled reference signal to control the switch circuit system to output an appropriate voltage or current waveform.

[0010] The additional communication interface can provide two-way data communication between the master control device and each local control device. This allows the local control device to provide status information (e.g., temperature, charging status, etc.) to the master control device. The master control device can in turn adjust the modulation index of the cascade module based on the status of the cascade module.

[0011] The master control device and the local control devices may utilize synchronization techniques to synchronize the reception of control information data elements and / or synchronize the control of module switching circuit systems, such as using pulse width modulation (PWM). The master control device may be configured to generate and send a synchronization signal to each local control device, the synchronization signal indicating when a control information data element is sent to a local control device and / or when to synchronize the control of switches of modules controlled by the local control device. For example, when a local control device detects a PWM synchronization event based on the synchronization signal, the local control device may reset a PWM counter used to generate a carrier signal. Similarly, when a local control device detects a data reception synchronization event, the local control device may capture a control information data element sent from the master control device.

[0012] In some embodiments, the local control device is configured to detect a synchronization event (e.g., a PWM synchronization event and / or a data reception synchronization event) based on the absence of data sent along a path or link between the master control device and the local control device. The local control device may monitor a duration that elapses after the end of each data segment, and if the duration reaches a threshold without receiving another data segment, the local control device may determine that a data absence event has occurred, and correspondingly, a synchronization event has occurred.

[0013] Other systems, devices, methods, features, and advantages of the subject matter described herein will be or will become apparent to those skilled in the art upon review of the following drawings and detailed description. All such additional systems, methods, features, and advantages are intended to be included within this description, to be within the scope of the subject matter described herein, and to be protected by the appended claims. Features of the exemplary embodiments should in no way be construed to limit the appended claims without expressly reciting such features in the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The details of the subject matter described herein, both as to its structure and operation, may be apparent from a study of the accompanying drawings, in which like reference numerals refer to like parts. The components in the drawings are not necessarily drawn to scale, with emphasis placed on illustrating the principles of the subject matter. Furthermore, all illustrations are intended to convey concepts in which relative dimensions, shapes, and other detailed attributes may be illustrated schematically rather than literally or precisely.

[0015] Figures 1A to 1CA block diagram depicting an exemplary embodiment of a modular energy system.

[0016] Figures 1D to 1E A block diagram depicting an exemplary embodiment of a control device for an energy system.

[0017] Figures 1F to 1G A block diagram depicts an exemplary embodiment of a modular energy system coupled to a load and a charge source.

[0018] Figures 2A to 2B is a block diagram depicting an exemplary embodiment of modules and a control system within an energy system.

[0019] Figure 2C A block diagram of an exemplary embodiment depicting the physical configuration of a module.

[0020] Figure 2D A block diagram depicting an exemplary embodiment of a physical configuration of a modular energy system.

[0021] Figures 3A to 3C is a block diagram depicting exemplary embodiments of modules having various electrical configurations.

[0022] Figures 4A to 4F is a schematic diagram depicting an exemplary embodiment of an energy source.

[0023] Figures 5A to 5C is a schematic diagram depicting an exemplary embodiment of an energy buffer.

[0024] Figures 6A to 6C is a schematic diagram depicting an exemplary embodiment of a converter.

[0025] Figures 7A to 7E A block diagram depicting an exemplary embodiment of a modular energy system having various topologies.

[0026] Fig. 8A is a plot depicting exemplary output voltages of the modules.

[0027] Figure 8B is a plot depicting exemplary multi-level output voltages for an array of modules.

[0028] Figure 8C 2 is a plot depicting exemplary reference and carrier signals that may be used with a pulse width modulation control technique.

[0029] Fig.8D 2 is a plot depicting exemplary reference and carrier signals that may be used with a pulse width modulation control technique.

[0030] Fig. 8E is a plot depicting an exemplary switching signal generated according to a pulse width modulation control technique.

[0031] Figure 8F Graph depicting an exemplary multi-level output voltage produced by superposition of output voltages from an array of modules under pulse width modulation control techniques.

[0032] Figures 9A to 9B A block diagram depicting an exemplary embodiment of a controller for a modular energy system.

[0033] Fig. 10A A block diagram depicts an exemplary embodiment of a multi-phase modular energy system having interconnected modules.

[0034] Fig. 10B To depict Fig. 10A Schematic diagram of an exemplary embodiment of an interconnection module in a multi-phase embodiment.

[0035] Fig. 10C A block diagram depicts an exemplary embodiment of a modular energy system having two subsystems connected together by an interconnect module.

[0036] Fig. 10D A block diagram depicts an exemplary embodiment of a three-phase modular energy system having interconnected modules supplying an auxiliary load.

[0037] Fig. 10E To depict Fig. 10D Schematic diagram of an exemplary embodiment of an interconnection module in a multi-phase embodiment.

[0038] Fig.10F A block diagram depicts another exemplary embodiment of a three-phase modular energy system having interconnected modules supplying an auxiliary load.

[0039] Figures 11A to 11B A block diagram is depicted to illustrate an exemplary embodiment of a modular energy system having a communication path connecting a master control device to local control devices.

[0040] Fig.12 is a block diagram depicting an exemplary embodiment of a single-phase energy system.

[0041] Fig.13 is a block diagram depicting an exemplary embodiment of a phased energy system.

[0042] Fig.14 is a block diagram depicting an exemplary embodiment of a three-phase energy system.

[0043] Fig.15 is a block diagram depicting the interface of an exemplary embodiment of a master control device.

[0044] Figures 16A to 16B is a block diagram depicting example components of an example embodiment of a coupling module.

[0045] Fig.17 is a block diagram depicting an exemplary embodiment of a local control device.

[0046] Fig.18 is a flow chart depicting an exemplary embodiment of a method of sending control information data elements to a local control device and outputting a voltage waveform based on the control information data packet.

[0047] Fig.19 is a flow chart depicting an exemplary embodiment of a method of sending a control information data element to a local control device.

[0048] Fig. 20 is a flow chart depicting an exemplary embodiment of a method of receiving a control information data element.

[0049] Fig.21 is a diagram of an exemplary data flow.

[0050] Fig. 22 is a flow chart depicting an exemplary embodiment of a method of receiving control information data elements using a synchronization signal.

[0051] Fig.23 is a diagram of an exemplary data flow.

[0052] Fig.24 is a flow chart depicting an exemplary embodiment of a method of waking up a local control device.

[0053] Fig.25A is a block diagram of an exemplary embodiment of a local control device.

[0054] Fig.25B is a schematic diagram depicting an exemplary embodiment of a communication connection between a master control device and a local control device.

[0055] Fig.25C is a schematic diagram depicting an exemplary embodiment of a communication connection between a master control device and a local control device.

[0056] Fig.26A is a block diagram of an exemplary embodiment of a synchronization unit.

[0057] Fig.26B is a schematic diagram of an exemplary embodiment of a comparator.

[0058] Fig.26C and 26D is a plot depicting the waveform of a signal associated with a synchronization unit.

[0059] Fig. 27 is a plot depicting a frequency modulated synchronization signal and the voltage level of a capacitor of a synchronization unit.

[0060] Fig.28 is a plot depicting a frequency modulated synchronization signal and a reset signal generated based on the frequency modulated synchronization signal.

[0061] Fig.29 is a flow chart depicting an exemplary embodiment of a method of synchronizing data capture events and PWM events.

[0062] Fig.30 is a flow chart depicting an exemplary embodiment of a method of synchronizing data capture events and PWM events.

[0063] Fig.31 is a plot depicting the jitter present in the switching signal output by the local control device.

[0064] Fig.32 is a plot depicting reduced jitter present on a switching signal output by a local control device. DETAILED DESCRIPTION

[0065] Before describing the subject matter of the present invention in detail, it should be understood that the present disclosure is not limited to the particular embodiments described, as such may, of course, vary. 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.

[0066] Before describing exemplary embodiments involving modular energy systems and their communication interfaces, it is useful to first describe these basic systems in more detail. Figures 1A to 10F The following sections describe various applications in which embodiments of modular energy systems may be implemented, embodiments of control systems or devices for modular energy systems, configurations of modular energy system embodiments relative to charging sources and loads, embodiments of individual modules, embodiments of topologies for arrangements of modules within the system, embodiments of control methods, embodiments of balanced operating characteristics of modules within the system, and embodiments of the use of interconnected modules.

[0067] Application Examples

[0068] Fixed applications are applications in which modular energy systems are located in fixed locations during use, but may be able to be transported to alternative locations when not in use. Module-based energy systems reside in static locations while providing electrical energy for consumption by one or more other entities, or storing or buffering energy for later consumption. Examples of fixed applications in which the embodiments disclosed herein may be used include, but are not limited to: energy systems for use or in one or more residential structures or sites, energy systems for use or in one or more industrial structures or sites, energy systems for use or in one or more commercial structures or sites, energy systems for use or in one or more government structures or sites (including both military and non-military use), energy systems for charging mobile applications described below (e.g., charge sources or charging stations), and systems that convert solar energy, wind power, geothermal energy, fossil fuels, or nuclear reactions into electricity for storage. Fixed applications often supply loads such as power grids and microgrids, motors, and data centers. Fixed energy systems can be used for storage or non-storage.

[0069] Mobile applications, sometimes referred to as traction applications, are typically mobile applications in which a module-based energy system is located on or within an entity and stores and provides electrical energy to be converted into power by an electric motor to move or assist in moving the entity. 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 move on or under land, on or under the sea, on or at sea and not in contact with land or sea (e.g., flying or hovering in the air) or through outer space. Examples of mobile entities that can be used with the embodiments disclosed herein include, but are not limited to, vehicles, trains, trams, ships, boats, aircraft, 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, bicycles, industrial vehicles, mining vehicles, aircraft (e.g., airplanes, helicopters, drones, etc.), marine vessels (e.g., commercial transport vessels, ships, yachts, boats, or other watercraft), submarines, locomotives or track-based vehicles (e.g., trains, trams, etc.), military vehicles, spacecraft, and satellites.

[0070] When describing embodiments herein, reference may be made to specific fixed applications (e.g., power grids, microgrids, data centers, cloud computing environments) or mobile applications (e.g., electric vehicles). Such references are made for ease of explanation and do not imply that a particular embodiment is limited to use with the particular mobile or fixed application. Embodiments of systems for providing power to electric motors may be used in both mobile and fixed applications. Although certain configurations may be more suitable for some applications than others, all exemplary embodiments disclosed herein are capable of use in both mobile and fixed applications unless otherwise stated.

[0071] Example of a module-based energy system

[0072] Figure 1A 1 is a block diagram depicting an exemplary embodiment of a module-based energy system 100. Here, the system 100 includes a control system 102, which is communicatively coupled to N converter source modules 108-1 to 108-N via communication paths or links 106-1 to 106-N, respectively. The modules 108 are configured to store energy and output energy to a load 101 (or other modules 108) as needed. In these embodiments, any number of two or more modules 108 (e.g., N is greater than or equal to two) may be used. The modules 108 may be connected to each other in a variety of ways, such as by connecting the modules 108 to each other with respect to each other. Figures 7A to 7E For ease of explanation, Figures 1A to 1C , the modules 108 are shown connected in series, or as a one-dimensional array, where the Nth module is coupled to the load 101.

[0073] The system 100 is configured to supply power to a load 101. The load 101 may be any type of load, such as a motor or an electrical grid. The system 100 is also configured to store power received from a charge source. Figure 1F To depict a block diagram of an exemplary embodiment of system 100, the system has a power input interface 151 for receiving power from charge source 150 and a power output interface for outputting power to load 101. In this embodiment, system 100 can receive and store power via interface 151 while outputting power via interface 152. Figure 1G 1 is a block diagram depicting another exemplary embodiment of a system 100 having a switchable interface 154. In this embodiment, the system 100 may select or may be instructed to select between receiving power from a charge source 150 and outputting power to a load 101. The system 100 may be configured to supply multiple loads 101, including both primary and auxiliary loads, and / or receive power from multiple charge sources 150, such as a utility-operated power grid and a local renewable energy source (e.g., solar energy).

[0074] Figure 1BAnother exemplary embodiment of the system 100 is depicted. Here, the control system 102 is implemented as a master control device (MCD) 112 that is communicatively coupled to N different local control devices (LCDs) 114-1 to 114-N via communication paths or links 115-1 to 115-N, respectively. Each LCD 114-1 to 114-N is communicatively coupled to one 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 LCD 114 and the module 108.

[0075] Figure 1C Another exemplary embodiment of the system 100 is depicted. Here, the MCD 112 is communicatively coupled to M different LCDs 114-1 through 114-M via communication paths or links 115-1 through 115-M, respectively. Each LCD 114 may be coupled to and control two or more modules 108. In the example shown here, each LCD 114 is communicatively coupled to two modules 108, such that the M LCDs 114-1 through 114-M are coupled to 2M modules 108-1 through 108-2M, respectively, via communication paths or links 116-1 through 116-2M.

[0076] The control system 102 may be configured as a single device of the entire system 100 (e.g., Figure 1A ), or may be distributed across or implemented as multiple devices (e.g., Figures 1B to 1C ). In some embodiments, the control system 102 may be distributed among the LCDs 114 associated with the modules 108 such that the MCD 112 is unnecessary and may be omitted from the system 100 .

[0077] Control system 102 may be configured to perform control using software (instructions stored in memory that can be executed by processing circuitry), hardware, or a combination thereof. One or more devices of control system 102 may each include processing circuitry 120 and memory 122 as shown here. Exemplary embodiments of processing circuitry and memory are further described below.

[0078] The control system 102 may have a communication interface for communicating with a device 104 external to the system 100 via a communication link or path 105. For example, the control system 102 (e.g., the MCD 112) may output data or information about the system 100 to another control device 104 (e.g., an electronic control unit (ECU) or a motor control unit (MCU) of a vehicle in mobile applications, a grid controller in stationary applications, etc.).

[0079] Communication paths or links 105, 106, 115, 116 and 118 ( Figure 2B ) may each be a wired (e.g., electrical, optical) or wireless communication path that communicates data or information bidirectionally in a parallel or serial manner. Data may be communicated in a standardized (e.g., IEEE, ANSI) or custom (e.g., proprietary) format. In automotive applications, communication path 115 may be configured to communicate according to a FlexRay or controller area network (CAN) protocol. Communication paths 106, 115, 116, and 118 may also provide wired power to supply operating power to system 102 directly from one or more modules 108. For example, operating power for each LCD 114 may be supplied solely by one or more modules 108 to which LCD 114 is connected, and operating power for MCD 112 may be supplied indirectly from one or more of modules 108 (e.g., through the power network of the vehicle).

[0080] The control system 102 is configured to control one or more modules 108 based on status information 160 received from the same or different one or more of the modules 108. Control may also be based on one or more other factors, such as the requirements of the load 101. Controllable aspects include, but are not limited to, one or more of the voltage, current, phase, and / or output power of each module 108.

[0081] The status information 160 of each module 108 in the system 100 may be communicated to the control system 102, which may independently control each module 108-1 ... 108-N. Other variations are also possible. For example, a particular module 108 (or a subset of modules) may be controlled based on the status information 160 of the particular module 108 (or a subset), based on the status information 160 of a different module 108 that is not the particular module 108 (or a subset), based on the status information 160 of all modules 108 other than the particular module 108 (or a subset), based on the status information 160 of the particular module 108 (or a subset) and the status information 160 of at least one other module 108 that is not the particular module 108 (or a subset), or based on the status information 160 of all modules 108 in the system 100.

[0082] The status information 160 may be information about one or more aspects, characteristics, or parameters of each module 108. Types of status information 160 include, but are not limited to, the following aspects of a module 108 or one or more components thereof (e.g., energy sources, energy buffers, converters, monitoring circuitry): a state of charge (SoC) of one or more energy sources of a module (e.g., a charge level of an energy source relative to its capacity, such as a fraction or percentage), a state of health (SOH) of one or more energy sources of a module (e.g., a figure of merit of a condition of an energy source compared to its ideal condition), a temperature of one or more energy sources or other components of a module, a capacity of one or more energy sources of a module, a voltage of one or more energy sources and / or other components of a module, a current of one or more energy sources and / or other components of a module, a state of power (SOP) (e.g., an available power limit of an energy source during discharge and / or charge), a state of energy (SOE) (e.g., a current level of available energy of an energy source relative to a maximum available energy of the source), and / or the presence or absence of a fault in any one or more of the components of a module.

[0083] The LCD 114 may be configured to receive status information 160 from each module 108, or determine status information 160 from monitored signals or data received from or within each module 108, and communicate the information to the MCD 112. In some embodiments, each LCD 114 may communicate raw collected data to the MCD 112, which then algorithmically determines status information 160 based on the raw data. The MCD 112 may then use the status information 160 of the modules 108 to make control determinations accordingly. The determinations may take the form of instructions, commands, or other information (e.g., the modulation index described herein) that may be utilized by the LCD 114 to maintain or adjust the operation of each module 108.

[0084] For example, the MCD 112 may receive the status information 160 and evaluate the information to determine differences between at least one module 108 (e.g., a component thereof) and at least one or more other modules 108 (e.g., similar components thereof). For example, the MCD 112 may determine that a particular module 108 is operating under one of the following conditions compared to one or more other modules 108: a relatively lower or higher SOC, a relatively lower or higher SOH, a relatively lower or higher capacity, a relatively lower or higher voltage, a relatively lower or higher current, a relatively lower or higher temperature, or with or without a fault. In such an example, the MCD 112 may output control information that causes a relevant aspect (e.g., output voltage, current, power, temperature) of the particular module 108 to be reduced or increased (depending on the condition). In this way, the utilization of the outlier module 108 (e.g., operating at a relatively lower SOC or higher temperature) may be reduced so as to cause the relevant parameter (e.g., SOC or temperature) of the module 108 to converge toward the parameter of one or more other modules 108.

[0085] Whether to adjust the operation of a particular module 108 may be determined by comparison of the status information 160 with a predetermined threshold, limit, or condition, and not necessarily by comparison with the status of other modules 108. The predetermined threshold, limit, or condition may be a static threshold, limit, or condition, such as a threshold, limit, or condition set by a manufacturer that does 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 160 of a module 108 indicates that the module will violate a predetermined threshold or limit (e.g., above or below the predetermined threshold or limit) or operate outside a predetermined range of acceptable operating conditions, then the MCD 112 may adjust the operation of the module 108. Similarly, if the status information 160 of a module 108 indicates the presence of an actual or potential fault (e.g., an alarm or warning) or indicates the absence or removal of an actual or potential fault, then the MCD 112 may adjust the operation of the module 108. Examples of faults include, but are not limited to, actual failure of a component, potential failure of a component, a short circuit or other overcurrent condition, an open circuit, an overvoltage condition, an inability to receive communications, receiving corrupted data, etc. Depending on the type and severity of the fault, utilization of the faulty module may be reduced to avoid damaging the module, or utilization of the module may be stopped entirely. For example, if a fault occurs in a given module, the MCD 112 or LCD 114 may cause the module to enter a bypass state as described herein.

[0086] The MCD 112 may control the modules 108 within the system 100 to achieve or converge toward a desired goal. For example, the goal may be to operate all modules 108 at the same or similar level to one another or within predetermined thresholds, limits, or conditions. This process is also referred to as balancing the operations or operating characteristics of the modules 108 or attempting to achieve a balance of the operations or operating characteristics. The term "balancing" as used herein does not require absolute equality between the modules 108 or their components, but is used in a broad sense to convey that the operation of the system 100 may be used to actively reduce differences in operation (or operating states) between the modules 108 that would otherwise exist.

[0087] The MCD 112 may communicate control information to the LCD 114 for the purpose of controlling the module 108 associated with the LCD 114. The control information may be, for example, a modulation index and a reference signal, a reference signal, or other signal as described herein. Each LCD 114 may use (e.g., receive and process) the control information to generate a switching signal that controls the operation of one or more components (e.g., a converter) within the associated module 108. In some embodiments, the MCD 112 generates the switching signal directly and outputs it to the LCD 114, which relays the switching signal to the intended module component.

[0088] All or a portion of the control system 102 may be combined with a system external control device 104 that controls one or more other aspects of a mobile or stationary application. When integrated in such a shared or common control device (or subsystem), control of the system 100 may be implemented in any desired manner, such as one or more software applications executed by the processing circuitry of the shared device, using the hardware of the shared device, or a combination thereof. Non-exhaustive examples of the external control device 104 include: a vehicle ECU or MCU with control capabilities for one or more other vehicle functions (e.g., motor control, drive interface control, traction control, etc.); a grid or microgrid controller responsible for one or more other power management functions (e.g., load interfacing, load power requirement prediction, transmission and switching, interfacing with charge sources (e.g., diesel, solar, wind), charge source power prediction, backup source monitoring, asset dispatch, etc.); and a data center control subsystem (e.g., environmental control, network control, backup control, etc.).

[0089] Figure 1D and 1E 1 is a block diagram depicting an exemplary embodiment of a shared or common control device (or system) 132 in which the control system 102 may be implemented. Figure 1D, the common control device 132 includes a main control device 112 and an external control device 104. The main control device 112 includes an interface 141 for communicating with the LCD 114 via a path 115, and an interface 142 for communicating with the external control device 104 via an internal communication bus 136. The external control device 104 includes an interface 143 for communicating with the main control device 112 via a bus 136, and an interface 144 for communicating with other entities of the overall application (e.g., components of a vehicle or power grid) via the communication path 136. In some embodiments, the common control device 132 may be integrated into a common housing or package, wherein the devices 112 and 104 are implemented as discrete integrated circuit (IC) chips or packages contained therein.

[0090] exist Figure 1E 104, the external control device 104 acts as a common control device 132, where the main control functionality is implemented as a component within the device 104. This component 112 may be or include software or other program instructions that are stored and / or hard-coded within the memory of the device 104 and executed by the processing circuit system of the component. The component may also include dedicated hardware. The component may be an independent module or core that has one or more internal hardware and / or software interfaces (e.g., application program interface (API)) for communicating with the operating software of the external control device 104. The external control device 104 may manage communication with the LCD 114 via interface 141 and communication with other devices via interface 144. In various embodiments, the devices 104 / 132 may be integrated into a single IC chip, may be integrated into multiple IC chips in a single package, or integrated into multiple semiconductor packages within a common housing.

[0091] exist Figure 1D and 1E In some embodiments, the main control functionality of the system 102 is shared in the common device 132, however, other divisions of shared control may be permitted. For example, a portion of the main control functionality may be distributed between the common device 132 and the dedicated MCD 112. In another example, at least a portion of the main control functionality and the local control functionality may both be implemented in the common device 132 (e.g., with the remaining local control functionality implemented in the LCD 114). In some embodiments, all of the control system 102 is implemented in the common device (or subsystem) 132. In some embodiments, the local control functionality is implemented within a device shared with another component of each module 108 (e.g., a battery management system (BMS)).

[0092] Examples of modules within the cascaded energy system

[0093] Module 108 may include one or more energy sources and power electronic converters, and optionally an energy buffer. Figures 2A to 2BA block diagram of an additional exemplary embodiment of a system 100 is depicted with a module 108 having a power converter 202, an energy buffer 204, and an energy source 206. The converter 202 may be a voltage converter or a current converter. Embodiments are described herein with reference to a voltage converter, but embodiments are not limited thereto. The converter 202 may be configured to convert a direct current (DC) signal from the energy source 206 into an alternating current (AC) signal and output the AC signal via a power connection 110 (e.g., an inverter). The converter 202 may also receive an AC or DC signal via connection 110 and apply it to the energy source 206 in either polarity in a continuous or pulsed form. The converter 202 may be or include an arrangement of switches (e.g., power transistors), such as a half bridge (H-bridge) of a full bridge. In some embodiments, the converter 202 includes only switches, and the converter (and the entire module) does not include a transformer.

[0094] The converter 202 may also (or alternatively) be configured to perform AC to DC conversion (e.g., rectifier), DC to DC conversion, and / or AC to AC conversion (e.g., in conjunction with an AC-DC converter) to charge a DC energy source from an AC source. In some embodiments, to perform the AC-AC conversion, the converter 202 may include a transformer, either alone or in combination with one or more power semiconductors (e.g., switches, diodes, thyristors, etc.). In other embodiments (e.g., embodiments where weight and cost are important factors), the converter 202 may be configured to perform the conversion using only power switches, power diodes, or other semiconductor devices and not a transformer.

[0095] Energy source 206 is preferably a robust energy storage device capable of outputting direct current and having an energy density suitable for energy storage applications of electric drive devices. Energy source 206 can be an electrochemical battery, such as a single battery cell or multiple battery cells connected together in a battery module or array, or any combination thereof. Figures 4A to 4D To illustrate a schematic diagram of an exemplary embodiment of the energy source 206, the energy source is configured as a single battery cell 402 ( Figure 4A ), a battery module having a plurality (eg, four) of batteries 402 connected in series ( Figure 4B ), a battery module having a single battery 402 connected in parallel ( Figure 4C ) and a battery module ( Figure 4D ). A non-exhaustive list of examples of battery types is set forth elsewhere herein.

[0096] Energy source 206 may also be a high energy density (HED) capacitor, such as an ultracapacitor or supercapacitor. Compared to the solid dielectric type of a typical electrolytic capacitor, a HED capacitor may be configured as a double layer capacitor (electrostatic charge storage device), a pseudocapacitor (electrochemical charge storage device), a hybrid capacitor (electrostatic and electrochemical), or other capacitor. In addition to higher capacitance, a HED capacitor may also have an energy density that is 10 to 100 times (or more) that of an electrolytic capacitor. For example, a HED capacitor may have a specific energy greater than 1.0 watt-hour / kilogram (Wh / kg), and a capacitance greater than 10 to 100 farads (F). As described above with respect to Figures 4A to 4D Although depicted as a battery, energy source 206 may be configured as a single HED capacitor or as a plurality of HED capacitors connected together in an array (eg, in series, parallel, or a combination thereof).

[0097] Energy source 206 may also be a fuel cell. The fuel cell may be a single fuel cell, a plurality of fuel cells connected in series or in parallel, or a fuel cell module. Examples of fuel cell types include proton exchange membrane fuel cells (PEMFC), phosphoric acid fuel cells (PAFC), solid acid fuel cells, alkaline fuel cells, high temperature fuel cells, solid oxide fuel cells, molten electrolyte fuel cells, and the like. Figures 4A to 4D The battery described, the energy source 206 can be configured as a single fuel cell or multiple fuel cells connected together in an array (e.g., in series, in parallel, or a combination thereof). The foregoing examples of source categories (e.g., batteries, capacitors, and fuel cells) and types (e.g., chemistry and / or structural configurations within each category) are not intended to form an exhaustive list, and one of ordinary skill in the art will recognize other variations that fall within the scope of the present subject matter.

[0098] Energy buffer 204 may suppress or filter current fluctuations across a DC line or link (eg, +V DCL and -V DCL ) to assist in maintaining the stability of the DC link voltage. These fluctuations may be relatively low (e.g., kilohertz) or high (e.g., megahertz) frequency fluctuations or harmonics caused by switching or other transients of converter 202. These fluctuations may be absorbed by buffer 204 rather than being passed to source 206 or to ports IO3 and IO4 of converter 202.

[0099] The power connection 110 is a connection for transferring energy or power to, from, and through the module 108. The module 108 can output energy from the energy source 206 to the power connection 110, where the energy can be transferred to other modules of the system or to a load. The module 108 can also receive energy from other modules 108 or charging sources (DC chargers, single-phase chargers, multi-phase chargers). The signal can also bypass the energy source 206 and pass through the module 108. The routing of energy or power into and out of the module 108 is performed by the converter 202 under the control of the LCD 114 (or another entity of the system 102).

[0100] exist Figure 2A In the embodiment of FIG. 1 , LCD 114 is implemented as a component separate from module 108 (e.g., not within a shared module housing) and is connected to converter 202 and is capable of communicating with the converter via communication path 116. Figure 2B In the embodiment of the present invention, LCD 114 is included as a component of module 108 and is connected to converter 202 and is capable of communicating with the converter via internal communication path 118 (e.g., a shared bus or discrete connection). LCD 114 may also be capable of receiving signals from energy buffer 204 and / or energy source 206 via path 116 or 118 and transmitting signals to the energy buffer and / or energy source.

[0101] The module 108 may also include a monitoring circuit system 208 configured to monitor (e.g., collect, sense, measure and / or determine) one or more aspects of the module 108 and / or its components, such as voltage, current, temperature or other operating parameters, which constitute the state information 160 (or may be used to determine the state information 160 via, for example, the LCD 114). The primary function of the state information 160 is to describe the state of one or more energy sources 206 of the module 108 so that it can be determined how much of the energy source is being utilized compared to other sources in the system 100, but state information 160 describing the state of other components (e.g., voltage, temperature and / or the presence of a fault in the buffer 204, temperature and / or the presence of a fault in the converter 202, the presence of a fault elsewhere in the module 108, etc.) may also be used to determine utilization. The monitoring circuit system 208 may include one or more sensors, shunts, voltage dividers, fault detectors, Coulomb counters, controllers, or other hardware and / or software configured to monitor such aspects. The monitoring circuit system 208 may be separate from each component 202, 204, and 206, or may be integrated with each component 202, 204, and 206 (eg, Figures 2A to 2B), or any combination thereof. In some embodiments, monitoring circuitry 208 may be part of or shared with a battery management system (BMS) of battery energy source 206. No discrete circuitry is required to monitor each type of status information 160, as a single circuit or device may be employed to monitor more than one type of status information 160, or more than one type of status information may otherwise be algorithmically determined without the need for additional circuitry.

[0102] LCD 114 may receive status information 160 (or raw data) about the module components via communication paths 116, 118. LCD 114 may also transmit information to the module components via paths 116, 118. Paths 116 and 118 may include diagnostic, measurement, protection, and control signal lines. The transmitted information may be a control signal for one or more module components. The control signal may be a switching signal of converter 202 and / or one or more signals requesting status information 160 from the module components. For example, LCD 114 may cause the status information 160 to be transmitted via paths 116, 118 by directly requesting the status information 160 or by applying an excitation (e.g., a voltage) to cause the status information 160 to be generated, in some cases in conjunction with a switching signal that places converter 202 in a particular state.

[0103] The physical configuration or layout of module 108 may take various forms. In some embodiments, module 108 may include a common housing in which all module components (e.g., converter 202, buffer 204, and source 206) are housed, along with other optional components such as an integrated LCD 114. In other embodiments, the various components may be separated in discrete housings that are secured together. Figure 2C To depict a block diagram of an exemplary embodiment of a module 108, the module has a first housing 220 that houses the module's energy source 206 and accompanying electronics, such as monitoring circuitry, a second housing 222 that houses the module, such as the converter 202, the energy buffer 204, and other accompanying electronics, such as monitoring circuitry, and a third housing 224 that houses the LCD 114 (not shown) of the module 108. In alternative embodiments, the module electronics and the LCD 114 may be housed within the same single housing. In still other embodiments, the module electronics, the LCD 114, and the energy source may be housed within the same single housing of the module 108. Electrical connections between the various module components may be made through the housings 220, 222, 224, and may be exposed on any of the housing exteriors for connection with other devices, such as other modules 108 or the MCD 112.

[0104] The modules 108 of the system 100 can be physically arranged relative to each other in various configurations depending on the needs of the application and the number of loads. For example, in a fixed application where the system 100 provides power to a microgrid, the modules 108 can be placed in one or more racks or other frames. Such a configuration may also be suitable for larger mobile applications, such as marine vessels. Alternatively, the modules 108 can be fixed together and located in a common housing referred to as a package. The rack or package may have its own dedicated cooling system shared across all modules. The package configuration is suitable for smaller mobile applications, such as electric vehicles. The system 100 can be implemented using one or more racks (e.g., for parallel supply to a microgrid) or one or more packages (e.g., serving different motors of a vehicle) or a combination thereof. Figure 2D To depict a block diagram of an exemplary embodiment of system 100 , the system is configured as a package having nine modules 108 that are electrically and physically coupled together within a common housing 230 .

[0105] Examples of these and other configurations are described in International Application No. PCT / US20 / 25366, filed on March 27, 2020, and entitled “Module-Based Energy Systems Capable of Cascaded and Interconnected Configurations, and Methods Related Thereto,” which is incorporated herein by reference in its entirety for all purposes.

[0106] Figures 3A to 3C 1 is a block diagram depicting exemplary embodiments of modules 108 having various electrical configurations. These embodiments are described as having one LCD 114 per module 108, wherein the LCD 114 is housed within the associated module, but the embodiments may be configured in other ways as described herein. Figure 3A A first exemplary configuration of module 108A within system 100 is depicted. Module 108A includes energy source 206, energy buffer 204, and converter 202A. Each component has a power connection port (e.g., terminal, connector), referred to herein as an IO port, into which power can be input and / or from which power can be output. Depending on the context, such ports may also be referred to as input ports or output ports.

[0107] Energy source 206 may be configured as any of the energy source types described herein (e.g., as described with respect to Figures 4A to 4DThe power source 206 may be a battery, a HED capacitor, a fuel cell, or other energy source type as described herein. Ports IO1 and IO2 of the energy source 206 may be connected to ports IO1 and IO2, respectively, of the energy buffer 204. The energy buffer 204 may be configured to buffer or filter high and low frequency energy pulsations that pass through the converter 202 to the buffer 204, which would otherwise degrade the performance of the module 108. The topology and components of the buffer 204 are selected to accommodate the maximum allowable amplitude of these high frequency voltage pulsations. Figures 5A to 5C Several (non-exhaustive) exemplary embodiments of the energy buffer 204 are depicted in the schematic diagram of FIG. Figure 5A In the embodiment, the buffer 204 is an electrolytic and / or film capacitor C EB ,exist Figure 5B The buffer 204 is composed of two inductors L EB1 and L EB2 and two electrolytic and / or film capacitors C EB1 and C EB2 The Z source network 710 is formed, and in Figure 5C The buffer 204 is composed of two inductors L EB1 and L EB2 , two electrolytic and / or film capacitors C EB1 and C EB2 And diode D EB A quasi-Z source network 720 is formed.

[0108] Ports IO3 and IO4 of energy buffer 204 may be connected to ports IO1 and IO2 , respectively, of converter 202A, which may be configured as any of the types of power converters described herein. Fig. 6A A schematic diagram of an exemplary embodiment of a converter 202A is depicted, which is configured as a DC-AC converter that can receive a DC voltage at ports IO1 and IO2 and switch to generate pulses at ports IO3 and IO4. The converter 202A can include a plurality of switches, and here, the converter 202A includes four switches S3, S4, S5, S6 arranged in a full-bridge configuration. The control system 102 or LCD 114 can independently control each switch via a control input line 118-3 to each gate.

[0109] The switches may be any suitable switch type, such as power semiconductors, such as metal oxide semiconductor field effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), or gallium nitride (GaN) transistors as shown here. The semiconductor switches may be operated at relatively high switching frequencies, thereby permitting the converter 202 to operate in pulse width modulation (PWM) mode as needed and respond to control commands in relatively short time intervals. This may provide high tolerance output voltage regulation and fast dynamic behavior in transient mode.

[0110] In this embodiment, the DC line voltage V DCL It can be applied to the converter 202 between the ports IO1 and IO2. V DCL Connected to ports IO3 and IO4, converter 202 can generate three different voltage outputs at ports IO3 and IO4: +V DCL , 0, and -V DCL The switch signal provided to each switch controls whether the switch is on (closed) or off (open). In order to obtain +V DCL , switches S3 and S6 are turned on, while S4 and S5 are turned off, and -V can be obtained by turning on switches S4 and S5 and turning off S3 and S6. DCL By turning on S3 and S5 and disconnecting S4 and S6 or by turning on S4 and S6 and disconnecting S3 and S5, the output voltage can be set to zero (including near zero) or a reference voltage. These voltages can be output from the module 108 via the power connection 110. Ports IO3 and IO4 of the converter 202 can be module IO ports 1 and 2 connected to (or forming) the power connection 110 to generate an output voltage for use with output voltages from other modules 108.

[0111] The control or switching signals for the embodiments of converter 202 described herein may be generated in different ways depending on the control technique used by system 100 to generate the output voltage of converter 202. In some embodiments, the control technique is a PWM technique, such as space vector pulse width modulation (SVPWM) or sinusoidal pulse width modulation (SPWM), or variations thereof. Fig. 8A A voltage versus time graph depicting an example of an output voltage waveform 802 of the converter 202. For ease of description, the embodiments herein will be described in the context of PWM control techniques, but the embodiments are not limited thereto. Other classes of techniques may be used. An alternative class is based on hysteresis, examples of which are described in International Publication Nos. WO 2018 / 231810A1, WO 2018 / 232403A1, and WO 2019 / 183553A1, which are incorporated herein by reference for all purposes.

[0112] Each module 108 may be configured with multiple energy sources 206 (e.g., two, three, four, or more). Each energy source 206 of a module 108 may be controllable (switchable) to supply power to a connection 110 (or receive power from a charge source) independently of the other sources 206 of the module. For example, all sources 206 may output power to the connection 110 (or may be charged) at the same time, or only one (or a subset) of the sources 206 may supply power (or may be charged) at any one time. In some embodiments, the sources 206 of a module may exchange energy therebetween, for example, one source 206 may charge another source 206. Each of the sources 206 may be configured as any of the energy sources described herein (e.g., a battery, a HED capacitor, a fuel cell). Each of the sources 206 may be of the same category (e.g., each may be a battery, each may be a HED capacitor, or each may be a fuel cell), or of different categories (e.g., a first source may be a battery and a second source may be a HED capacitor or a fuel cell, or a first source may be a HED capacitor and a second source may be a fuel cell).

[0113] Figure 3B A block diagram depicting an exemplary embodiment of module 108B, which is in a dual energy source configuration with a primary energy source 206A and a secondary energy source 206B. Ports IO1 and IO2 of primary source 202A can be connected to ports IO1 and IO2 of energy buffer 204. Module 108B includes a converter 202B with an additional IO port. Ports IO3 and IO4 of buffer 204 can be connected to ports IO1 and IO2 of converter 202B, respectively. Ports IO1 and IO2 of secondary source 206B can be connected to ports IO5 and IO2 of converter 202B, respectively (and also connected to port IO4 of buffer 204).

[0114] In this exemplary embodiment of module 108B, primary energy source 202A supplies the average power required by the load along with other modules 108 of system 100. Secondary source 202B may serve the function of auxiliary energy source 202 by providing additional power at load power peaks or absorbing excess power or otherwise.

[0115] As mentioned, both primary source 206A and secondary source 206B may be utilized simultaneously or at separate times depending on the switching state of converter 202B. If simultaneously, then electrolytic and / or film capacitors (C ES ) can be parallel to Figure 4E The source 206B depicted in FIG. 1 is placed to act as an energy buffer for the source 206B, or the energy source 206B may be configured to utilize a source 206B parallel to the source 206B. Figure 4F A HED capacitor of another energy source (e.g., a battery or fuel cell) as depicted in FIG.

[0116] Figure 6B and 6C Schematic diagrams depicting exemplary embodiments of converters 202B and 202C, respectively. Converter 202B includes switch circuitry sections 601 and 602A. Section 601 includes switches S3 to S6 configured as a full bridge in a similar manner to converter 202A, and is configured to selectively couple IO1 and IO2 to either IO3 and IO4, thereby changing the output voltage of module 108B. Section 602A includes switches S1 and S2, which are configured as a half bridge and coupled between ports IO1 and IO2. Coupled inductor L C Connected between port IO5 and node 1 between switches S1 and S2, switch section 602A is a bidirectional converter that can regulate voltage (or reverse current) (boost or buck). Switch section 602A can generate two different voltages at node 1, which is referenced to +V at port IO2. DCL2 The current drawn from or input to the energy source 202B can be adjusted by using, for example, a pulse width modulation technique or a hysteresis control method for switching switches S1 and S2 to adjust the coupled inductor L. C Other techniques may also be used.

[0117] Converter 202C differs from 202B in that switch portion 602B includes switches S1 and S2 configured as a half-bridge and coupled between ports IO5 and IO2. C Connected between the port IO1 and a node 1 present between switches S1 and S2, the switch portion 602B is configured to regulate voltage.

[0118] Control system 102 or LCD 114 can independently control each switch of converters 202B and 202C via control input line 118-3 to each gate. Fig. 6A In some embodiments, LCD 114 (rather than MCD 112) generates the switching signal for the converter switch. Alternatively, MCD 112 may generate the switching signal, which may be communicated directly to the switch, or relayed through LCD 114. In some embodiments, driver circuitry for generating the switching signal may be present in or may be associated with MCD 112 and / or LCD 114.

[0119] The aforementioned zero voltage configuration of the converter 202 (S3 and S5 turned on and S4 and S6 turned off, or S4 and S6 turned on and S3 and S5 turned off) may also be referred to as the bypass state for a given module. This bypass state may be entered if a fault is detected in a given module, or if a system fault is detected that warrants shutting down more than one (or all modules) in the array or system. The fault in the module may be detected by the LCD 114, and the control switching signal of the converter 202 may be set to engage the bypass state without intervention by the MCD 112. Alternatively, the fault information for a given module may be communicated to the MCD 112 via the LCD 114, and the MCD 112 may then determine whether to engage the bypass state, and if so, may communicate an instruction to engage the bypass state to the LCD 114 associated with the module having the fault, at which point the LCD 114 may output a switching signal to cause the bypass state to be engaged.

[0120] In embodiments where the module 108 includes three or more energy sources 206, the converters 202B and 202C may be scaled accordingly such that each additional energy source 206B is coupled to an additional IO port leading to an additional switch circuitry portion 602A or 602B, depending on the needs of the particular source. For example, a dual source converter 202 may include both switch portions 202A and 202B.

[0121] A module 108 having multiple energy sources 206 is capable of performing additional functions, such as energy sharing between sources 206, energy capture from within an application (e.g., regenerative braking), charging a primary source through a secondary source even when the overall system is in a discharged state, and active filtering of the module output. Active filtering functions can also be performed by modules having typical electrolytic capacitors instead of secondary energy sources. Examples of these functions are described in more detail in International Application No. PCT / US20 / 25366, filed on March 27, 2020, entitled “Module-Based Energy Systems Capable of Cascaded and Interconnected Configurations, and Methods Related Thereto” and International Publication No. WO 2019 / 183553, filed on March 22, 2019, entitled “Systems and Methods for Power Management and Control”, both of which are incorporated herein by reference in their entirety for all purposes.

[0122] Each module 108 may be configured to supply its one or more energy sources 206 to one or more auxiliary loads. An auxiliary load is a load that requires a lower voltage than the primary load 101. Examples of auxiliary loads may be, for example, an onboard power network of an electric vehicle or an HVAC system of an electric vehicle. For example, a load of the system 100 may be an electric vehicle motor or one of the phases of the electrical grid. This embodiment may allow for complete decoupling between the electrical characteristics (terminal voltage and current) of the energy source and the electrical characteristics of the load.

[0123] Figure 3C A block diagram of an exemplary embodiment of module 108C is depicted, the module being configured to supply power to first auxiliary load 301 and second auxiliary load 302, wherein module 108C includes a circuit similar to Figure 3B The energy source 206, the energy buffer 204, and the converter 202B are coupled together in an energy source, an energy buffer, and a converter manner. The first auxiliary load 301 requires a voltage equivalent to the voltage supplied from the source 206. The load 301 is coupled to IO ports 3 and 4 of the module 108C, which are in turn coupled to ports IO1 and IO2 of the source 206. The source 206 can output power to both the power connection 110 and the load 301. The second auxiliary load 302 requires a constant voltage lower than the constant voltage of the source 206. The load 302 is coupled to IO ports 5 and 6 of the module 108C, which are coupled to ports IO5 and IO2 of the converter 202B, respectively. The converter 202B may include a switching portion 602 having a coupled inductor L coupled to port IO5 C ( Figure 6B ). The energy supplied by source 206 can be supplied to load 302 through switch portion 602 of converter 202B. Assuming load 302 has an input capacitor (if not, a capacitor can be added to module 108C), switches S1 and S2 can be commutated to adjust the coupled inductor L C The voltage across the source 206 and the current through the coupled inductor are regulated, and thus a stable constant voltage is generated for the load 302. This regulation can reduce the voltage of the source 206 to a lower voltage required by the load 302.

[0124] Module 108C can thus be configured to supply one or more first auxiliary loads in the manner described with respect to load 301, wherein the one or more first loads are coupled to IO ports 3 and 4. Module 108C can also be configured to supply one or more second auxiliary loads in the manner described with respect to load 302. If there are multiple second auxiliary loads 302, then for each additional load 302, module 108C can be scaled with additional dedicated module output ports (e.g., 5 and 6), additional dedicated switch sections 602, and additional converter IO ports coupled to the additional sections 602.

[0125] Energy source 206 may thus supply power to any number of auxiliary loads (eg, 301 and 302), as well as supplying a corresponding portion of the system output power required by primary load 101. Power flow from source 206 to the various loads may be adjusted as desired.

[0126] The module 108 may be configured to have two or more energy sources 206 ( Figure 3B ) and is configured to supply the first and / or second auxiliary load ( ) by adding a switch portion 602 and a converter port 105 to each additional source 206B or second auxiliary load 302 Figure 3C ). Additional module IO ports (e.g., 3, 4, 5, 6) may be added as needed. Modules 108 may also be configured as interconnect modules to exchange energy (e.g., for balancing) between two or more arrays, two or more packages, or two or more systems 100 as further described herein. This interconnect functionality may likewise be combined with multi-source and / or multi-auxiliary load supply capabilities.

[0127] The control system 102 may perform various functions with respect to the components of the modules 108A, 108B, and 108C. These functions may include managing the utilization (usage) of each energy source 206, protecting the energy buffer 204 from over-current, over-voltage, and high-temperature conditions, and controlling and protecting the converter 202.

[0128] For example, in order to manage the utilization of each energy source 206 (e.g., by increasing, decreasing, or maintaining to adjust), the LCD 114 may receive one or more monitored voltages, temperatures, and currents from each energy source 206 (or monitoring circuitry). The monitored voltage may be at least one of the voltages of each elementary component or the voltages of the entire group of elementary components (e.g., the voltages of the battery array, the HED capacitor array, and / or the fuel cell array) that are independent of other components of the source 206 (e.g., each individual battery cell, HED capacitor, and / or fuel cell), and preferably all of them. Similarly, the monitored temperature and current may be at least one of the temperature and current of each elementary component or the temperature and current of the entire group of elementary components, or any combination thereof, that are independent of other components of the source 206, and preferably all of them. The monitored signal may be status information 160, which the LCD 114 may utilize to perform one or more of: calculation or determination of actual capacity, actual state of charge (SOC) and / or state of health (SOH) of an elementary component or group of elementary components; setting or outputting a warning or alarm indication based on the monitored and / or calculated status information 160; and / or transmission of the status information 160 to the MCD 112. The LCD 114 may receive control information (e.g., modulation index, synchronization signal) from the MCD 112, and use this control information to generate switching signals for the converter 202, which manage the utilization of the source 206.

[0129] To protect the energy buffer 204, the LCD 114 may receive one or more monitored voltages, temperatures, and currents from the energy buffer 204 (or monitoring circuitry). The monitored voltages may be independent of each basic component of the buffer 204 (e.g., C EB , C EB1 , C EB2 , L EB1 , L EB2 , D EB ) or the voltage of the group of basic components or buffer 204 as a whole (e.g., between IO1 and IO2 or between IO3 and IO4), preferably all. Similarly, the monitored temperature and current may be at least one of the temperature and current of each basic component of the buffer 204 independent of other components or the temperature and current of the group of basic components or buffer 204 as a whole, or any combination thereof, preferably all. The monitored signal may be status information 160, which the LCD 114 may use to perform one or more of the following: set or output an alert or alarm indication; communicate the status information 160 to the MCD 112; or control the converter 202 to adjust (increase or decrease) the utilization of the overall source 206 and module 108 for buffer protection.

[0130] To control and protect converter 202, LCD 114 may receive control information (e.g., a modulated reference signal or a reference signal and a modulation index) from MCD 112, which may be used with PWM techniques in LCD 114 to generate control signals for each switch (e.g., S1 to S6). LCD 114 may receive current feedback signals from current sensors of converter 202, which may be used for overcurrent protection along with one or more fault status signals from driver circuits (not shown) of the converter switches, which may carry information about the fault status (e.g., short circuit or open circuit fault mode) of all switches of converter 202. Based on this data, LCD 114 may make decisions about the combination of switching signals to be applied to manage the utilization of module 108, and may bypass or disconnect converter 202 (and the entire module 108) from system 100.

[0131] If the module 108C is controlled to supply the second auxiliary load 302, the LCD 114 may receive one or more monitored voltages (e.g., the voltage between IO ports 5 and 6) and one or more monitored currents (e.g., the coupled inductor L1) in the module 108C. C Based on these signals, LCD 114 can adjust the switching cycles of S1 and S2 (e.g., by adjusting the modulation index or reference waveform) to control (and stabilize) the voltage of load 302.

[0132] Example of cascaded energy system topology

[0133] Two or more modules 108 may be coupled together in a cascaded array that outputs a voltage signal formed by the superposition of discrete voltages generated by each module 108 within the array. Fig. 7A 1 is a block diagram of an exemplary embodiment depicting a topology of the system 100, wherein N modules 108-1, 108-2, ... 108-N are coupled together in series to form a series array 700. In this embodiment and all embodiments described herein, N may be any integer greater than one. The array 700 includes a first system IO port SIO1 and a second system IO port SIO2, across which an array output voltage is generated. The array 700 may be used as a DC or single-phase AC energy source for a DC or AC single-phase load, which may be connected to SIO1 and SIO2 of the array 700. Fig. 8A is a voltage versus time plot depicting an exemplary output signal produced by a single module 108 having a 48 volt energy source. Figure 8B is a voltage versus time plot depicting an exemplary single-phase AC output signal produced by an array 700 having six 48V modules 108 coupled in series.

[0134] The system 100 can be arranged in a wide variety of topologies to meet the different needs of the application. The system 100 can provide multi-phase power (e.g., two-phase, three-phase, four-phase, five-phase, six-phase, etc.) to the load by using multiple arrays 700, where each array can generate an AC output signal with a different phase angle.

[0135] Figure 7B 1 is a block diagram depicting a system 100 having two arrays 700-PA and 700-PB coupled together. Each array 700 is one-dimensional and is formed by a series connection of N modules 108. The two arrays 700-PA and 700-PB can each generate a single-phase AC signal, where the two AC signals have different phase angles PA and PB (e.g., 180 degrees apart). The IO port 1 of the module 108-1 of each array 700-PA and 700-PB can form or be connected to the system IO ports SIO1 and SIO2, respectively, which in turn can serve as the first output of each array, which can provide two-phase power to a load (not shown). Or alternatively, ports SIO1 and SIO2 can be connected to provide single-phase power from two parallel arrays. The IO ports 2 of the modules 108-N of each array 700-PA and 700-PB may serve as the second output of each array 700-PA and 700-PB on the opposite end of the array from the system IO ports SIO1 and SIO2, and may be coupled together at a common node and optionally used for an additional system IO port SIO3 as needed, which may serve as a neutral point. This common node may be referred to as a rail, and the IO ports 2 of the modules 108-N of each array 700 may be referred to as being on the rail side of the array.

[0136] Figure 7C A block diagram is depicted of a system 100 having three arrays 700-PA, 700-PB, and 700-PC coupled together. Each array 700 is one-dimensional and is formed by a series connection of N modules 108. The three arrays 700-1 and 700-2 can each generate a single-phase AC signal, wherein the three AC signals have different phase angles PA, PB, PC (e.g., 120 degrees apart). The IO port 1 of the module 108-1 of each array 700-PA, 700-PB, and 700-PC can form or be connected to the system IO ports SIO1, SIO2, and SIO3, respectively, which in turn can provide three-phase power to the load (not shown). The IO port 2 of the module 108-N of each array 700-PA, 700-PB, and 700-PC can be coupled together at a common node, and optionally used for an additional system IO port SIO4 as needed, which can act as a neutral point.

[0137] about Figure 7B and 7CThe concepts described for the two-phase and three-phase embodiments of the present invention can be extended to systems 100 that produce power for still more phases. For example, a non-exhaustive list of additional examples includes: a system 100 having four arrays 700, each of which is configured to produce a single-phase AC signal having a different phase angle (e.g., 90 degrees apart); a system 100 having five arrays 700, each of which is configured to produce a single-phase AC signal having a different phase angle (e.g., 72 degrees apart); and a system 100 having six arrays 700, each of which is configured to produce a single-phase AC signal having a different phase angle (e.g., 60 degrees apart).

[0138] The system 100 may be configured such that the arrays 700 are interconnected at electrical nodes between the modules 108 within each array. Fig.7D To depict a block diagram of system 100, the system has three arrays 700-PA, 700-PB, and 700-PC coupled together in a combined series and delta arrangement. Each array 700 includes a first series connection of M modules 108 coupled to a second series connection of N modules 108, where M is two or greater, where N is two or greater. The delta configuration is formed by interconnections between the arrays, which can be placed in any desired location. In this embodiment, IO port 2 of module 108-(M+N) of array 700-PC is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PA, IO port 2 of module 108-(M+N) of array 700-PB is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PC, and IO port 2 of module 108-(M+N) of array 700-PA is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PB.

[0139] Fig. 7E To depict a block diagram of system 100, the system has three arrays 700-PA, 700-PB, and 700-PC coupled together in a combined series and delta arrangement. This embodiment is similar to Fig.7D In this embodiment, IO port 2 of module 108-M of array 700-PC is coupled to IO port 1 of module 108-1 of array 700-PA, IO port 2 of module 108-M of array 700-PB is coupled to IO port 1 of module 108-1 of array 700-PC, and IO port 2 of module 108-M of array 700-PA is coupled to IO port 1 of module 108-1 of array 700-PB. Fig.7D and 7EThe arrangement can be implemented with as few as two modules in each array 700. The combined delta and series configuration enables efficient exchange of energy between all modules 108 of the system (phase balanced) and the phases of the grid or load, and also allows the total number of modules 108 in the array 700 to be reduced to obtain the desired output voltage.

[0140] In the embodiments described herein, while it is advantageous that the number of modules 108 in each array 700 within the system 100 is the same, this is not required and different arrays 700 may have different numbers of modules 108. Furthermore, each array 700 may have modules 108 that are all of the same configuration (e.g., all modules are 108A, all modules are 108B, all modules are 108C, or other) or different configurations (e.g., one or more modules are 108A, one or more modules are 108B, and one or more modules are 108C, or other). Thus, the range of topologies of the system 100 contemplated herein is broad.

[0141] Control Method Examples

[0142] As mentioned, control of system 100 may be performed according to various methods such as hysteresis or PWM. Several examples of PWM include space vector modulation and sinusoidal pulse width modulation, where the switching signal for converter 202 is generated using a phase-shifted carrier technique that sequentially alternates the utilization of each module 108 to equally distribute power therebetween.

[0143] Figures 8C to 8F A plot diagram depicting an exemplary embodiment of a phase-shifted PWM control method that can generate a multi-level output PWM waveform using an incrementally shifted bi-level waveform. The X-level PWM waveform can be generated by summing (X-1) / 2 bi-level PWM waveforms. These bi-level waveforms can be generated by comparing a reference waveform Vref with a carrier wave that is incrementally shifted by 360° / (X-1). The carrier wave is triangular, but embodiments are not limited thereto. Figure 8C A nine-level example (using four modules 108) is shown in . The carrier is incrementally shifted by 360° / (9-1)=45° and compared to Vref. Fig. 8E The resulting two-level PWM waveforms are shown in . These two-level waveforms can be used as switching signals for the semiconductor switches (e.g., S1 to S6) of the converter 202. Fig. 8EFor an example, for a one-dimensional array 700 including four modules 108 each having a converter 202, a 0° signal is used to control S3, and a 180° signal is used for S6 of the first module 108-1, a 45° signal is used for S3 and a 225° signal is used for S6 of the second module 108-2, a 90° signal is used for S3 and a 270° signal is used for S6 of the third module 108-3, and a 135° signal is used for S3 and a 315° signal is used for S6 of the fourth module 108-4. The signal of S3 is complementary to S4, and the signal of S5 is complementary to S6, with sufficient dead time to avoid breakdown of each half bridge. Figure 8F An exemplary single-phase AC waveform produced by superposition (summing) of the output voltages from four modules 108 is depicted.

[0144] An alternative is to utilize positive and negative reference signals with the first (N-1) / 2 carriers. Fig.8D A nine-level example is shown in FIG. In this example, the 0° to 135° switching signal ( Fig. 8E ) By comparing +Vref with Fig.8D The 0° to 135° carrier is generated, and the 180° to 315° switching signal is generated by comparing -Vref with Fig.8D However, in the latter case, the logic of the comparison is reversed. Other techniques such as a state machine decoder can also be used to generate the gate signals for the switches of converter 202.

[0145] In a multi-phase system embodiment, the same carrier may be used for each phase, or the carrier set may be shifted as a whole for each phase. For example, in a three-phase system with a single reference voltage (Vref), each array 700 may use a reference voltage with a voltage such as Figure 8C and 8D , but the carrier of the second phase is shifted 120 degrees compared to the carrier of the first phase, and the carrier of the third phase is shifted 240 degrees compared to the carrier of the first phase. If a different reference voltage can be used for each phase, then the phase information can be carried in the reference voltage and the same carrier can be used for each phase. In many cases, the carrier frequency will be fixed, but in some exemplary embodiments, the carrier frequency can be adjusted, which can help reduce losses in the EV motor under high current conditions.

[0146] Appropriate switching signals may be provided to each module by the control system 102. For example, depending on the one or more modules 108 that the LCD 114 controls, the MCD 112 may provide Vref and an appropriate carrier signal to each LCD 114, and the LCD 114 may then generate the switching signal. Or all LCDs 114 in the array may be provided with all carrier signals, and the LCD may select the appropriate carrier signal. In another example, the LCD 114 may use, for example, as described below with reference to Fig.11A and 11B The PWM controller described is used to generate the carrier signal.

[0147] The relative utilization of each module 108 may be adjusted based on the state information 160 to perform balancing or one or more parameters as described herein. Balancing of parameters may involve adjusting the utilization to minimize parameter differences over time compared to a system that does not perform individual module utilization adjustments. The utilization may be the relative amount of time that the module 108 is discharging when the system 100 is in a discharging state, or the relative amount of time that the module 108 is charging when the system 100 is in a charging state.

[0148] As described herein, the modules 108 can be balanced relative to other modules in the array 700, which can be referred to as intra-array or intra-phase balancing, and different arrays 700 can be balanced relative to each other, which can be referred to as inter-array or inter-phase balancing. Arrays 700 of different subsystems can also be balanced relative to each other. The control system 102 can simultaneously perform any combination of intra-phase balancing, inter-phase balancing, utilization of multiple energy sources within a module, active filtering, and auxiliary load supply.

[0149] Fig. 9A 9 is a block diagram depicting an exemplary embodiment of an array controller 900 of a control system 102 for a single-phase AC or DC array. The array controller 900 may include a peak detector 902, a divider 904, and an intra-phase (or intra-array) balancing controller 906. The array controller 900 may receive a reference voltage waveform (Vr) and state information 160 (e.g., state of charge (SOCi), temperature (Ti), capacity (Qi), and voltage (Vi)) about each of the N modules 108 in the array as inputs, and generate a normalized reference signal, such as a voltage waveform (Vrn) and a modulation index (Mi) as outputs. The peak detector 902 detects a peak value (Vpk) of Vr, which may be specific to the phase that the controller 900 is operating and / or balancing. The divider 904 generates Vrn by dividing Vr by its detected Vpk. The intra-phase balance controller 906 uses Vpk along with the state information 160 (eg, SOCi, Ti, Qi, Vi, etc.) to generate a modulation index Mi for each module 108 within the array 700 being controlled.

[0150] The modulation index and Vrn can be used to generate the switching signal of each converter 202. The modulation index can be a number between zero and one (including zero and one). For a particular module 108, the normalized reference signal Vrn can be modulated or scaled by Mi, and this modulated reference signal (Vrnm) can be based on the Figures 8C to 8F The PWM technique described or according to other techniques is used as Vref (or -Vref). In this way, the modulation index can be used to control the PWM switching signal provided to the converter switching circuit system (e.g., S3 to S6 or S1 to S6), and thus adjust the operation of each module 108. For example, a module 108 controlled to maintain normal or full operation can receive Mi of one, while a module 108 controlled to be less than normal or full operation can receive Mi less than one, and a module 108 controlled to stop power output can receive Mi of zero. This operation can be performed by the control system 102 in various ways, such as by the MCD 112 outputting Vrn and Mi to the appropriate LCD 114 for modulation and switch signal generation, by the MCD 112 performing modulation and outputting the modulated Vrnm to the appropriate LCD 114 for switch signal generation, or by the MCD 112 performing modulation and switch signal generation and outputting the switch signal directly to the LCD of each module 108 or the converter 202. Vrn may be sent continuously, and Mi sent at regular intervals, such as once per cycle of Vrn, once per minute, and so on.

[0151] The controller 906 may generate Mi for each module 108 using any type or combination of the state information 160 described herein (e.g., SOC, temperature (T), Q, SOH, voltage, current). For example, when using SOC and T, if the SOC is relatively high and the temperature is relatively low compared to other modules 108 in the array 700, then the module 108 may have a relatively high Mi. If the SOC is relatively low or the T is relatively high, then the module 108 may have a relatively low Mi, resulting in a lower utilization than other modules 108 in the array 700. The controller 906 may determine Mi so that the sum of the module voltages does not exceed Vpk. For example, Vpk may be the sum of the product of the voltage of the source 206 of each module and the Mi of the module (e.g., Vpk=M 1 V 1 +M 2 V 2 +M 3 V 3 ...+M N V N etc.) Different combinations of modulation indices, and therefore corresponding voltage contributions of the modules, may be used, but the overall generated voltage should remain the same.

[0152] The controller 900 may control operation within a range that does not prevent the power output requirement of the system from being achieved at any one time (e.g., during maximum acceleration of the EV) so that the SOC of the energy sources in each module 108 remain balanced or converge to a balanced condition if they are unbalanced, and / or so that the temperature of the energy sources or other components (e.g., energy buffers) in each module remain balanced or converge to a balanced condition if they are unbalanced. The power flow into and out of the modules may be regulated so that the capacity differences between the sources do not cause SOC deviations. The balance of SOC and temperature may indirectly cause a certain balance of SOH. Voltage and current may be directly balanced as desired, but in many embodiments, the primary goal of the system is to balance SOC and temperature, and the balance of SOC may cause a balance of voltage and current in a highly symmetrical system where the modules have similar capacities and impedances.

[0153] Since it is not possible to balance all parameters simultaneously (e.g., balancing one parameter may further unbalance another parameter), balancing any combination of two or more parameters (SOC, T, Q, SOH, V, I) may be applied, with one of them being prioritized depending on the requirements of the application. Balancing SOC may be prioritized over other parameters (T, Q, SOH, V, I), but an exception may occur if one of the other parameters (T, Q, SOH, V, I) reaches a severe imbalance condition outside of a threshold.

[0154] Balancing between arrays 700 of different phases (or arrays of the same phase, for example, if parallel arrays are used) may be performed simultaneously with intra-phase balancing. Fig. 9B An exemplary embodiment of an Ω phase (or Ω array) controller 950 is depicted, which is configured for operation in an Ω phase system 100 having at least Ω arrays 700, where Ω is any integer greater than one. The controller 950 may include an interphase (or interarray) controller 910 and Ω intraphase balancing controllers 906-PA ... 906-PΩ for phases PA to PΩ, and a peak detector 902 and divider 904 ( Fig. 9A ). The in-phase controller 906 may generate Mi for each module 108 of each array 700, as described with respect to Fig. 9AThe interphase balancing controller 910 is configured or programmed to balance aspects of the modules 108 across the entire multi-dimensional system, e.g., between arrays of different phases. This can be accomplished by injecting a common mode (e.g., a neutral point shift) into the phases or by using an interconnect module (described herein) or by both. Common mode injection involves introducing a phase and amplitude shift into the reference signals VrPA to VrPΩ to produce a normalized waveform VrnPA to VrnPΩ to compensate for imbalances in one or more arrays, and is further described in International Application No. PCT / US20 / 25366, incorporated herein.

[0155] Controllers 900 and 950 (and balancing controllers 906 and 910) may be implemented in hardware, software, or a combination thereof within control system 102. Controllers 900 and 950 may be implemented within MCD 112, partially or completely distributed within LCD 114, or may be implemented independently of MCD 112 and LCD 114 as discrete controllers.

[0156] Interconnect (IC) Module Examples

[0157] Modules 108 may be connected between modules of different arrays 700 for the purpose of exchanging energy between arrays, acting as a source of auxiliary loads, or both. Such modules are referred to herein as interconnect (IC) modules 108IC. IC modules 108IC may be implemented in any of the module configurations (108A, 108B, 108C) already described and in any of the module configurations to be described herein. IC modules 108IC may include any number of one or more energy sources, optional energy buffers, switch circuit systems for supplying energy to one or more arrays and / or for supplying power to one or more auxiliary loads, control circuit systems (e.g., local control devices), and monitoring circuit systems for collecting status information 160 about the IC module itself or its various loads (e.g., SOC of an energy source, temperature of an energy source or energy buffer, capacity of an energy source, SOH of an energy source, voltage and / or current measurements involving IC modules, voltage and / or current measurements involving auxiliary loads, etc.).

[0158] Fig. 10ATo depict a block diagram of an exemplary embodiment of a system 100, the system is capable of generating Ω phase power using Ω arrays 700-PA to 700-PΩ, where Ω can be any integer greater than one. In this and other embodiments, the IC module 108IC can be located on the track side of the array 700 so that the array 700 to which the module 108IC is connected (in this embodiment, the arrays 700-PA to 700-PΩ) is electrically connected between the module 108IC and the outputs to the load (e.g., SIO1 to SIOΩ). Here, the module 108IC has Ω IO ports for connecting to the IO port 2 of each module 108-N of the array 700-PA to 700-PΩ. In the configuration depicted here, the module 108IC can perform phase balancing by selectively connecting one or more energy sources of the module 108IC to one or more of the arrays 700-PA to 700-PΩ (or to none of the outputs, or equally to all of the outputs if phase balancing is not required). The system 100 may be controlled by a control system 102 (not shown, see Figure 1A )control.

[0159] Fig. 10B 1 is a schematic diagram depicting an exemplary embodiment of module 108IC. In this embodiment, module 108IC includes energy source 206, which is connected to energy buffer 204, which in turn is connected to switch circuit system 603. Switch circuit system 603 may include switch circuit system units 604-PA to 604-PΩ for independently connecting energy source 206 to each of arrays 700-PA to 700-PΩ, respectively. A respective switch configuration may be used for each unit 604, which in this embodiment is configured as a half bridge with two semiconductor switches S7 and S8. Each half bridge is controlled by control line 118-3 from LCD 114. This configuration is similar to that described with respect to Figure 3A As described with respect to converter 202, switching circuitry 603 may be configured in any arrangement and employing any switch type (eg, MOSFET, IGBT, Silicon, GaN, etc.) suitable for the requirements of the application.

[0160] The switch circuit system unit 604 is coupled between the positive terminal and the negative terminal of the energy source 206 and has an output connected to the IO port of the module 108 IC. The units 604-PA to 604-PΩ can be controlled by the control system 102 to switch the voltage +V IC or -V IC1 to Ω. The control system 102 may control the switch circuit system 603 according to any desired control technique, including the PWM and hysteresis techniques mentioned herein. Here, the control circuit system 102 is implemented as an LCD 114 and an MCD 112 (not shown). The LCD 114 may receive monitoring data or status information 160 from the monitoring circuit system of the module 108 IC. This monitoring data and / or other status information 160 derived from this monitoring data may be output to the MCD 112 for system control as described herein. For the purpose of synchronizing the modules 108 of the system 100 with one or more carrier signals (not shown) (e.g., a sawtooth signal for PWM), the LCD 114 may also receive timing information (not shown) ( Figures 8C to 8D ).

[0161] For inter-phase balancing, more energy from source 206 may be supplied proportionally to any one or more of arrays 700-PA through 700-PΩ that have a relatively lower charge than the other arrays 700. The supply of this supplemental energy to a particular array 700 allows the energy output of those cascaded modules 108-1 through 108-N in that array 700 to be reduced relative to the unsupplied phase arrays.

[0162] For example, in some exemplary embodiments where PWM is applied, the LCD 114 may be configured to receive a normalized voltage reference signal (Vrn) (from the MCD 112), e.g., VrnPA to VrnPΩ, for each of the one or more arrays 700 to which the module 108IC is coupled. The LCD 114 may also receive modulation indexes MiPA to MiPΩ for the switch cells 604-PA to 604-PΩ of each array 700, respectively, from the MCD 112. The LCD 114 may modulate each corresponding Vrn (e.g., multiply Vrn by the modulation index) (e.g., VrnA by MiA) using a modulation index directly coupled to the switch segments of the array, and then utilize a carrier signal to generate a control signal for each switch cell 604. In other embodiments, the MCD 112 may perform the modulation and output a modulated voltage reference waveform for each cell 604 directly to the LCD 114 of the module 108IC. In yet other embodiments, all processing and modulation may be performed by a single control entity, which may output control signals directly to each unit 604 .

[0163] This switching may be modulated so that power from energy source 206 is supplied to array 700 at appropriate intervals and durations. Such methods may be implemented in a variety of ways.

[0164] Based on the collected state information 160 of the system 100, such as the current capacity (Q) and SOC of each energy source in each array, the MCD 112 can determine the total charge for each array 700 (e.g., the total charge of the array can be determined as the sum of the capacity of each module of the array multiplied by the SOC). The MCD 112 can determine whether a balanced or unbalanced condition exists (e.g., by using the relative difference thresholds and other metrics described herein), and generate the modulation index MiPA to MiPΩ for each switch unit 604-PA to 604-PΩ accordingly.

[0165] During balancing operation, Mi of each switch unit 604 may be set to a value that causes the energy source 206 and / or energy buffer 204 to supply the same or similar amount of net energy to each array 700 over time. For example, Mi of each switch unit 604 may be the same or similar and may be set to a level or value that causes the module 108 IC to perform a net release or time-averaged release of energy to one or more arrays 700-PA to 700-PΩ during balancing operation so that the module 108 IC is consumed at the same rate as other modules 108 in the system 100. In some embodiments, Mi of each unit 604 may be set to a level or value that does not cause a net release or time-averaged release of energy (causing a net energy release of zero) during balancing operation. This may be applicable in the case where the module 108 IC has a lower total charge than other modules in the system.

[0166] When an unbalanced condition occurs between the arrays 700, the modulation index of the system 100 may then be adjusted to converge toward a balanced condition or minimize further differences. For example, the control system 102 may cause the module 108IC to discharge more to the array 700 with a low charge than other modules, and may also cause the modules 108-1 to 108-N of the low array 700 to discharge relatively less (e.g., based on a time average). The relative net energy contributed by the module 108IC is increased compared to the modules 108-1 to 108-N of the assisted array 700, and also compared to the amount of net energy contributed by the module 108IC to the other arrays. This may be achieved by increasing the Mi of the switch cells 604 supplying the low array 700 and by reducing the modulation index of the modules 108-1 to 108-N of the low array 700 in a manner that maintains the Vout of the low array at an appropriate or desired level and maintaining the modulation index of the other switch cells 604 supplying other higher arrays relatively unchanged (or causing it to decrease).

[0167] Figures 10A to 10BThe configuration of the modules 108IC in may be used alone to provide inter-phase or inter-array balancing to a single system, or may be used in combination with one or more other modules 108IC each having an energy source and one or more switch sections 604 coupled to one or more arrays. For example, a module 108IC having Ω switch sections 604 coupled to Ω different arrays 700 may be combined with a second module 108IC having one switch section 604 coupled to one array 700, such that the two modules are combined to serve a system 100 having Ω+1 arrays 700. Any number of modules 108IC may be combined in this manner, with each module coupled to one or more arrays 700 of the system 100.

[0168] Furthermore, the IC modules may be configured to exchange energy between two or more subsystems of the system 100 . Fig. 10C To depict a block diagram of an exemplary embodiment of system 100, the system has a first subsystem 1000-1 and a second subsystem 1000-2 interconnected by IC modules. Specifically, subsystem 1000-1 is configured to supply three-phase power PA, PB, and PC to a first load (not shown) by means of system I / O ports SIO1, SIO2, and SIO3, and subsystem 1000-2 is configured to supply three-phase power PD, PE, and PF to a second load (not shown) by means of system I / O ports SIO4, SIO5, and SIO06, respectively. For example, subsystems 1000-1 and 1000-2 can be configured as different packages that supply power to different motors of an EV or can be configured as different racks that supply power to different microgrids.

[0169] In this embodiment, each module 108IC is coupled to the first array of subsystem 1000-1 (via IO port 1) and the first array of subsystem 1000-2 (via IO port 2), and each module 108IC can be electrically connected to each other module 108IC via I / O ports 3 and 4, which are similar to those described above. Figure 3C 108C of each module 108IC is coupled to the energy source 206 of each module 108IC described in FIG. 108C. This connection places the sources 206 of modules 108IC-1, 108IC-2, and 108IC-3 in parallel, and thus the energy stored and supplied by modules 108IC is brought together through this parallel arrangement. Other arrangements, such as rigid connections, may also be used. Modules 108IC are housed within the common housing of subsystem 1000-1, however, the interconnect modules may be external to the common housing and physically located between the common housings of the two subsystems 1000 as independent entities.

[0170] Each module 108IC has a switch unit 604-1 coupled to IO port 1 and a switch unit 604-2 coupled to I / O port 2, as shown in FIG. Fig. 10B As described herein. Thus, in order to balance between subsystems 1000 (e.g., between packages or between racks), a particular module 108IC may supply relatively more energy to either or both of the two arrays to which it is connected (e.g., module 108IC-1 may supply to array 700-PA and / or array 700-PD). The control circuit system may monitor the relative parameters of the arrays of the different subsystems (e.g., SOC and temperature) and adjust the energy output of the IC modules to compensate for the imbalance between the arrays or phases of the different subsystems in the same manner as described herein to compensate for the imbalance between two arrays of the same rack or package. Because all three modules 108IC are connected in parallel, energy can be efficiently exchanged between any and all arrays of the system 100. In this embodiment, each module 108IC supplies two arrays 700, but other configurations may be used, including a single IC module for all arrays of the system 100 and a configuration with one dedicated IC module for each array 700 (e.g., six IC modules for six arrays, each with one switch unit 604). In all cases of multiple IC modules, energy sources may be coupled together in parallel to share energy as described herein.

[0171] In systems with IC modules between phases, interphase balancing can also be performed by neutral point shifting (or common mode injection) as described above. This combination allows for more robust and flexible balancing under a wider range of operating conditions. The system 100 can determine appropriate situations in which to perform interphase balancing using only neutral point shifting, only interphase energy injection, or a combination of both.

[0172] The IC module may also be configured to supply power to one or more auxiliary loads 301 (at the same voltage as source 206 ) and / or one or more auxiliary loads 302 (at a voltage stepped down from source 302 ). Fig. 10D To depict a block diagram of an exemplary embodiment of a three-phase system 100A having two modules 108IC connected to perform inter-phase balancing and supply auxiliary loads 301 and 302 . Fig. 10E1 is a schematic diagram depicting this exemplary embodiment of system 100, with emphasis placed on modules 108IC-1 and 108IC-2. Here again, control circuitry 102 is implemented as LCD 114 and MCD 112 (not shown). LCD 114 may receive monitoring data from modules 108IC (e.g., SOC of ES1, temperature of ES1, Q of ES1, voltages of auxiliary loads 301 and 302, etc.) and may output this and / or other monitoring data to MCD 112 for system control, as described herein. Each module 108IC may include a switching portion 602A (or a switching portion 602B) for each load 302 supplied by the module. Figure 6C 602B) and each switch section 602 can be controlled to maintain a necessary voltage level for the load 302 through the LCD 114 either independently or based on a control input from the MCD 112. In this embodiment, each module 108IC includes a switch section 602A connected together to supply one load 302, but this is not required.

[0173] Fig.10F To illustrate a block diagram of another exemplary embodiment of a three-phase system configured to supply power to one or more auxiliary loads 301 and 302, the three-phase system has modules 108IC-1, 108IC-2, and 108IC-3. In this embodiment, modules 108IC-1 and 108IC-2 are configured in the same manner, as described with respect to Figures 10D to 10E Module 108IC-3 is configured to play a purely auxiliary role and does not actively inject voltage or current into any array 700 of system 100. In this embodiment, module 108IC-3 can be configured as Figure 3B The module 108C includes converters 202B, 202C ( Figures 6B to 6C ), the converter has one or more auxiliary switch sections 602A but omits switch section 601. Thus, the one or more energy sources 206 of module 108IC-3 are interconnected in parallel with those of modules 108IC-1 and 108IC-2, and thus, this embodiment of system 100 is configured with additional energy for supplying auxiliary loads 301 and 302 and for maintaining the charge on sources 206A of modules 108IC-1 and 108IC-2 by being connected in parallel with source 206 of module 108IC-3.

[0174] The voltage and capacity of the energy source 206 of each IC module can be the same as the source 206 of the other modules 108-1 to 108-N of the system, but this is not required. For example, in which one module 108IC applies energy to multiple arrays 700 ( Fig. 10A) to allow the IC module to discharge at the same rate as the modules of the phase array itself, a relatively high capacity may be required. If the module 108IC also supplies an auxiliary load, an even larger capacity may be required to permit the IC module to supply the auxiliary load and discharge at relatively the same rate as the other modules.

[0175] Second life energy source example

[0176] The energy source 206 described herein can be used in the system 100 described herein in a first life application and a second life application. The first life of the source 206 is the original application in which the source 206 is used. For example, the first life application is a first embodiment in which the source 206 is put into use by the first customer of the source 206 after its original manufacture (rather than refurbishment). The user of the source 206 in its first life will generally have received the source 206 from the manufacturer, distributor, or original equipment manufacturer (OEM). The battery 206 used in the first life application will generally have the same electrochemistry (e.g., will have the same lithium ion electrochemical variant (e.g., LFP, NMC)), and will have the same nominal voltage, and will have a minimum capacity variation (e.g., 5% or less) across the battery pack or system. Using an energy storage system with the battery in the first life application of the battery 206 will cause the battery 206 to have a longer service life in the first life application, and after being removed from the first life application, the battery 206 will be more similar in capacity degradation than the battery from the first life application without the energy storage system.

[0177] As used herein, a "second life" application refers to any application or implementation of the source 206 subsequent to the first life application (e.g., a second implementation, a third implementation, a fourth implementation, etc.). A second life energy source refers to any energy source (e.g., a battery or HED capacitor) implemented in the second life application of the source.

[0178] An example of a first life application for battery 206 is within an energy storage system for an EV. Then, at the end of the life (e.g., after 100,000 miles of driving, or after a threshold amount of battery degradation within the battery pack), battery 206 may be removed from the battery pack, optionally refurbished and tested, and then implemented in a second life application, which may be, for example, used within a stationary energy storage system (e.g., residential, commercial, or industrial energy buffering, EV charging station energy buffering, renewable energy (e.g., wind, solar, hydroelectric), energy buffering, etc.) or another mobile energy storage system (e.g., a battery pack for an electric car, bus, train, or truck). Similarly, the first life application may be a first stationary application, and the second life application may be a stationary or mobile application.

[0179] For the second life application, the system 100 may select and / or utilize the sources 206 to minimize (or at least reduce) any differences in initial capacity and nominal voltage. For example, sources 206 having a capacity difference of 5% or greater may be included within the system 100 and may be operated to provide energy to the load. In another example, an operator or an automated system may select sources 206 for the system 100 that have a capacity difference within a threshold amount, for example, to reduce the initial capacity difference between the sources of the system 206. If the module 108 is compatible with both the first and second life applications (e.g., with or without reconfiguration), the module 108 may be selected for the second life application based on the capacity difference of the sources 206 of the module 108.

[0180] The system 100 can adjust the utilization of each source 206 individually so that the sources 206 within the system 100 or the battery pack of the system 100 are relatively balanced in terms of SOC or total charge (SOC multiplied by capacity) when the battery pack or system 100 is discharged, even though the sources 206 in the system 100 can have widely varying capacities. Similarly, the system 100 can maintain balance when the battery pack or system 100 is charged. The sources 206 can vary not only in capacity, but also in nominal voltage, power rating, electrochemical type (e.g., a combination of LFP batteries and NMC batteries), etc. Therefore, the system 100 can be used so that all modules 206 within the system 100 or each battery pack of the system 100 are second life energy sources with various combinations of different characteristics (or so that a combination of first life energy sources and second life energy sources are used).

[0181] In one instance, the system 100 may include a second useful life energy source 206 (and optionally may include one or more first useful life energy sources 206) having an energy capacity variation of 2% or greater, 5% or greater, 10% or greater, 15% or greater, 20% or greater, or 25% or greater, 30% or greater, 5% to 30%, 10% to 30% and / or 20% to 30%.

[0182] In another example, the system 100 may include a second energy life source 206 (and optionally may include one or more first life energy sources 206) having an energy capacity per mass density change of 2% or greater, 5% or greater, 10% or greater, 15% or greater, 20% or greater, or 25% or greater, 30% or greater, 5% to 30%, 10% to 30% and / or 20% to 30%.

[0183] In another example, the system 100 may include a second useful life energy source 206 (and optionally may include one or more first useful life energy sources 206) having a peak power per mass density variation of 2% or greater, 5% or greater, 10% or greater, 15% or greater, 20% or greater, or 25% or greater, 30% or greater, 5% to 30%, 10% to 30%, and / or 20% to 30%.

[0184] In another example, the system 100 may include a second service life energy source 206 (and optionally may include one or more first service life energy sources 206) having a nominal voltage variation of 2% or greater, 5% or greater, 10% or greater, 15% or greater, 20% or greater, or 25% or greater, 30% or greater, 5% to 30%, 10% to 30% and / or 20% to 30%.

[0185] In another example, the system 100 may include a second service life energy source 206 (and optionally may include one or more first service life energy sources 206) having an operating voltage range variation of 2% or greater, 5% or greater, 10% or greater, 15% or greater, 20% or greater, or 25% or greater, 30% or greater, 5% to 30%, 10% to 30% and / or 20% to 30%.

[0186] In another example, the system 100 may include a second service life energy source 206 (and optionally may include one or more first service life energy sources 206) having a maximum specified current rise time variation of 2% or greater, 5% or greater, 10% or greater, 15% or greater, 20% or greater, or 25% or greater, 30% or greater, 5% to 30%, 10% to 30% and / or 20% to 30%.

[0187] In another example, the system 100 may include a second useful life energy source 206 (and optionally may include one or more first useful life energy sources 206) having a specified peak current variation of 2% or greater, 5% or greater, 10% or greater, 15% or greater, 20% or greater, or 25% or greater, 30% or greater, 5% to 30%, 10% to 30% and / or 20% to 30%.

[0188] A change of X% (e.g., 5% or greater or 5% to 30%) may be satisfied by a change between a module 108 having the highest value for the parameter and a module 108 having the lowest value for the parameter within the system 100. For example, the system 100 may satisfy a change of 5% or greater in capacity where the capacity of the module 108 having the lowest capacity source 206 is 95% of the capacity of the module 108 having the highest capacity source 206, or less than the capacity of the module 108 having the highest capacity source 206. For each of the embodiments and parameters disclosed herein, the time at which the system 100 having one or more second life sources satisfies the X% change condition for the parameter may be when the system 100 is installed, when the system 100 is commissioned, after replacing one source 206 with another source 206, after the system 100 has been in operation for 10 hours or more, after the system 100 has been in operation for 100 hours or more, after the system 100 has been in operation for 1000 hours or more, and / or after the system 100 has been in operation for 10,000 hours or more. For example, a capacity change of 5% or more may occur after 1000 hours of operation of the system 100, even though the capacity change was not present at commissioning. This reflects the ability of embodiments of the system 100 to continue to operate and account for capacity differences between sources 206 that grow over time.

[0189] In another example, the system 100 may include a second life energy source 206 (and optionally may include one or more first life energy sources 206) having a variation of electrochemical types (e.g., lithium-ion batteries and non-lithium-ion batteries, or different lithium-ion batteries (e.g., any combination of NMC, LFP, LTO, or other lithium-ion battery types)).

[0190] The system 100 may include a second useful life energy source 206 (and optionally may include one or more first useful life energy sources 206 ) having any combination of the characteristics provided in the foregoing examples.

[0191] Examples of communication interfaces and control techniques in cascaded energy systems

[0192] Figures 11A to 11B1 is a block diagram depicting an exemplary embodiment of a modular energy system 100 having a communication path 115 that connects an MCD 112 to an LCD 114 of a module 108 (e.g., modules 108-1 to 108-N in arrays 700-PA to 700-PC). In general, the MCD 112 sends control information to the LCD 114 via the communication path 115. As described in more detail below, the MCD 112 and the LCD 114 may include a communication interface that enables the MCD 112 and the LCD 114 to communicate via the communication path 115. For example, the MCD 112 includes a control interface 1120 for communicating control information to the LCD 114 via communication paths 115-1 to 115-3, an information interface 1130 for communicating information, such as status information 160, to and from the LCD 114 via communication path 108, and a synchronization interface 1140 for sending synchronization signals to the LCD 114 via communication paths or links 1141-1 to 1141-3.

[0193] LCD 114 uses (eg, receives and processes) the control information to generate switching signals that control the operation of one or more components within module 108 (eg, power converter 202). Fig. 11B 108, but each LCD 114 may be communicatively coupled with one or more modules 108 as described above. In this example, the modules 108 are arranged into three arrays 700-PA, 700-PB, and 700-PC of cascaded modules 108. The arrays 700-PA, 700-PB, and 700-PC may each generate a single-phase AC signal, wherein the three AC signals have different phase angles PA, PB, PC for phases A, B, and C (e.g., the three-phase AC outputs are 120 degrees apart). For example, the array 700-PA may generate a single-phase AC signal for phase A, the array 700-PB may generate a single-phase AC signal for phase B, and the array 700-PC may generate a single-phase signal for phase C. Each array 700-PA, 700-PB, and 700-PC includes an "N" number of modules 108, which may be the same or different for the arrays 700-PA, 700-PB, and 700-PC.

[0194] MCD 112 includes a controller 950. Controller 950 may include an inter-phase (or inter-array) controller 910 ( Fig. 9B ) and the intra-phase balance controller 906 ( Fig. 9B ), and peak detector 902 and divider 904 ( Fig. 9A). The controller 950 is configured to receive one or more reference signals 1105, such as a reference voltage for each phase (e.g., Va, Vb, and Vc) and / or a reference current for each phase (e.g., Ia, Ib, and Ic) and state information 160. The controller 150 is also configured to generate a normalized reference signal VrnPA to VrnP from each phase-specific reference VrPA to VrPC based on the reference signal 1105 and the state information 160. The controller 906 within each phase of the controller 150 may also generate a modulation index Mi for each module 108 in the array 700 of the system 100 based on the reference signal 1105 and the state information 160. For example, the intra-phase controller 906-PA may generate MiPA1 to MiPAn for modules 108-1 to 108-n in the array 700-PA; the intra-phase controller 906-PB may generate MiPB1 to MiPBn for modules 108-1 to 108-n in the array 700-PA; and the intra-phase controller 906-PC may generate MiPC1 to MiPCn for modules 108-1 to 108-n in the array 700-PC.

[0195] Although shown as reference voltage waveforms, the normalized reference signals VrnPA, VrnPB, and VrnPC output by the controller 950 include reference currents or reference voltages for each of the three phases, e.g., reference current waveforms or reference voltage waveforms, depending on the operating mode of the system 100. For example, when the system 100 is in a grid connection mode such that the converter 202 of the module 108 of the system 100 is connected to the grid and operates like a current source, the converter 202 of the system 100 generates an output AC signal having the same voltage level, frequency, and phase of the grid. In the grid connection mode, the reference signal 1105 may include a reference current based on the current waveform of the grid, or data representing characteristics of the current waveform (e.g., phase, frequency, magnitude, etc.). When the system 100 is in a grid independent (e.g., grid island) mode, the system 100 may operate like a voltage source, and the converter 202 of the system 110 may generate an output AC signal having the last known voltage level, frequency, and phase of the grid before the grid is disconnected. In the grid independent mode, the reference signal 1105 may include a reference voltage based on these characteristics. Each normalized reference signal VrnPA, VrnPB, and VrnPC represents a reference voltage waveform or current waveform that the array 700-PA, 700-PB, and 700-PC including the module 108 will emulate with the generated AC output signal, for example, at a higher voltage or current level.

[0196] As described above, module 108 may be based on Figures 8C to 8FThe PWM technique described or according to other techniques uses a reference signal as Vref (or -Vref). The controller 950 can generate a normalized reference signal for each array 700 and a modulation index Mi for each module 108 in each array 700. In this example, when the system 100 is used for multi-phase operation (e.g., split-phase, three-phase, etc.), the controller 950 is configured to perform inter-phase balancing (e.g., in addition to intra-phase balancing) by scaling (e.g., amplifying or reducing) the normalized reference signal independently for each phase. In a single-phase implementation where the system includes a single array 700, the controller 900 can be used to generate a normalized reference signal for the array 700 using a peak detector 902 and a divider 904, and generate a modulation index Mi for each module in the array 700 using an intra-phase balancing controller 906, as described above.

[0197] For each phase A, B, and C, the MCD 112 sends the same normalized reference signal for that phase to the LCD 114 of each module 108 in the array 700. That is, the MCD 112 may send a normalized reference signal VrnPA to the LCD 114 of the module 108 in the array 700-PA; the MCD 112 may send a normalized reference signal VrnPB to the LCD 114 of the module 108 in the array 700-PB; and the MCD 112 may send a normalized reference signal VrnPC to the LCD 114 of the module 108 in the array 700-PC.

[0198] In some implementations, for each phase A, B, and C, the MCD 112 also sends the modulation index Mi for each module 108 in the array 700 for that phase to the LCD 114 of each module 108 in the array 700 for that phase. That is, the MCD 112 may send the modulation index MiPA1 for the module 108-1 in the array 700-PA to the LCD 114 for the modules 108-1 through 108-N in the array 700-PA; the MCD 112 may send the modulation index MiPA2 for the module 108-2 in the array 700-PA to the LCD 114 for the modules 108-1 through 108-N in the array 700-PA; and the MCD 112 may send the modulation index MiPA1 for the module 108-N in the array 700-PA to the LCD 114 for the modules 108-1 through 108-N in the array 700-PA.

[0199] The system 100 may include respective communication paths 115-1, 115-2, and 115-3 for each array 700-PA, 700-PB, and 700-PC, respectively. The MCD 112 may use a control interface 1120 to send control information including a normalized reference signal Vrn and a modulation index Mi to the modules 108 in the array 700 via the communication paths 115 for the array 700. For example, the MCD 112 may send control information including a normalized reference signal VrnPA and modulation indexes MiPA1 (for module 108-1), MiPA2 (for module 108-2) to MiPAn (for module 108-N) to each LCD 114 of each module 108-1 to 108-N in the array 700-PA via respective communication paths 115-1 to 115-n connecting the MCD 112 to the LCDs 114 of these modules 108.

[0200] In some embodiments, each communication path 115 is a serial or parallel path configured to provide unidirectional communication from the MCD 112 to the LCD 114 of each module 108 in the array (e.g., array 700-PA, 700-PB, or 700-PC). In some embodiments, each communication path 115 is a serial or parallel bidirectional path that enables bidirectional communication between the MCD 112 and the LCD 114 of each module 108 in the array (e.g., array 700-PA, 700-PB, or 700-PC). In some embodiments, the communication paths 115 can be connected in a daisy chain, a star network topology, a mesh topology, or another suitable configuration.

[0201] The communication path 115 may include the RS-485 physical layer and control interface 1120 of the MCD 112, and the corresponding control interface 1742 ( Fig.17 ) may include a differential half-duplex serial synchronous interface. In this example, the communication path 115 may include twisted pair wiring that connects the control interface 1120 of the MCD 112 to the control interface 1742 of the LCD 114 of each array 700-PA, 700-PB, and 700-PC. The communication path 115 may be a unidirectional time-deterministic communication path with a data sample time that is a factor of the carrier frequency of the PWM signal of each module. Other suitable paths may also be used. Time determinism means that the control information data elements sent through the communication path 115 are sent according to a defined time period. That is, the data sample time is constant, and the time between consecutive communication data elements can be constant so that each LCD 114 can access the time when each control information data element will arrive.

[0202] Each module 108 may have an identifier, such as an assigned identifier. The identifier for the module 108 enables the MCD 112 to distinguish each module 108 from each other module 108 and to specify which modulation index to use for which module 108. Each module 108 in an array (e.g., array 700-PA, 700-PB, or 700-PC) may have an identifier that is unique to the module 108 relative to the other modules in the array. For example, the identifiers for the modules 108 in the array 700-PA may all be unique within a particular implemented system such that they are different from one another.

[0203] In some embodiments, the MCD 112 sends control information to the modules 108 in the array (e.g., array 700-PA, 700-PB, or 700-PC) in the form of data elements that include control information (e.g., encode the control information). These control information data elements may be in the form of one or more data packets per control information data element or a data frame for each control information data element. Each control information data element of the array 700 for the modules 108 may include a normalized reference signal Vrn for the modules 108 (e.g., all modules 108) in the array 700, a modulation index Mi for one of the modules 108 in the array 700, and an identifier for one of the modules 108 in the array 700. In other examples, the control information data element may include the modulation index Mi and identifiers for multiple modules 108 in the array 700. However, if less data (e.g., fewer modulation indices and identifiers) is sent in each control information data element, the MCD 112 may send updated reference signals to the modules 108 in the array 700 faster.

[0204] The MCD 112 may periodically send control information data elements to the LCDs 114 of the modules 108 in the array (e.g., array 700-PA, 700-PB, or 700-PC), for example, based on a specified time period according to an order that defines the order in which the updated modulation index is sent to the modules 108. For example, if the order for the array 700-PA is module 108-1, module 108-2, and so on to 108-N, the MCD 112 may send a first control information data element to all modules 108-1 to 108-N in the array 700-PA, the first control information data element including a normalized reference signal VrnPA for all modules 108-1 to 108-N in the array 700-PA, a modulation index MiPA1 for module 108-1, and an identifier for module 108-1. Next, the MCD 112 may send a second control information data element to all modules 108-1 to 108-N in the array 700-PA, the second control information data element including the normalized reference signal VrnPA for all modules 108-1 to 108-N in the array 700-PA, the modulation index MiPA2 for module 108-2, and an identifier for module 108-2. After reaching module 108-N in the order described and sending the control information data element including the normalized reference signal VrnPA for all modules 108-1 to 108-N in the array 700-PA, the modulation index MiPAn for module 108-N, and an identifier for module 108-N, the MCD 112 may restart by sending the updated control information data element for module 108-1. The MCD 112 may send control information data elements to each other array 700-PB and 700-PC in a similar manner.

[0205] MCD 112 can use defined data protocol to send each control information data element. The control information data element can be in the form of one or more data packets. Each data packet can include one or more data segments. Each control information data element includes multiple parts. The multiple parts can include a first part with two or more bits, the two or more bits are allocated to represent the identifier for module 108, for example, the identifier for module 108 is encoded. The multiple parts can include a second part with two or more bits, the two or more bits are allocated to represent the modulation index Mi for the module 108 identified by the identifier. The multiple parts can include a third part with two or more bits, the two or more bits are allocated to represent the normalized reference signal Vrn for the module 108 in the array 700 containing the module 108. The first part, the second part and the third part can be arranged in any predetermined order within the control information data element. The control information data element can also optionally include one or more bits for error detection (e.g., cyclic redundancy check (CRC)). Each portion may be allocated a specific bit position in each byte of the control information data element so that its position within the data element does not vary.Each portion may extend across different bytes of the control information data element depending on the length of the portion.

[0206] In addition to the communication path or link 115 for sending control information to the LCD 114, the system 100 may also include another communication path or link 1108 for exchanging data between the MCD 112 and each LCD 114. For example, the communication path 1108 may be used to send status information 160 from each module 108 to the MCD 112. The communication path 1108 may be a serial or parallel bidirectional path that connects the MCD 112 to the LCD 114 of each module 108 in an array (e.g., arrays 700-PA, 700-PB, or 700-PC). Each array 700-PA, 700-PB, and 700-PC may have a separate communication path 1108, or all arrays 700-PA, 700-PB, and 700-PC may share a common communication path 1108. In some implementations, the communication path 1108 is bidirectional (from the MCD 112 to the LCD 114 and from the LCD 114 to the MCD 112) and is not time-deterministic. The communication path 1108 may be implemented as a CAN bus to couple the MCD 112 to each LCD 114 for communication using the CAN protocol. In this example, the information interface 1130 may be a CAN interface. Other suitable types of communication paths may also be used instead of CAN.

[0207] Using a combination of a unidirectional serial time-deterministic path for controlling converter 202 and a bidirectional non-time-deterministic path for other data exchange can provide performance advantages, especially for applications with limited bandwidth, such as applications where communication is performed over twisted pair. For example, this enables faster communication of a normalized reference signal from MCD 112 to LCD 114, while also ensuring timely updating of the modulation index and enabling error correction using CRC bits. Packing one modulation index into each control information data element can ensure that the normalized reference signal for all modules 108 is updated every frame (e.g., whenever a control information data element is sent), while the modulation index for each module 108 is updated 1 / N times every frame, where N is the number of modules 108 in an array (e.g., array 700-PA, 700-PB, or 700-PC).

[0208] Each module 108 includes its LCD 114, a converter 202 including switching circuitry, and an energy source 206, such as one or more batteries. Generally, LCD 114 decodes control information data elements received from MCD 112 and controls the switching circuitry of converter 202 using the decoded control information.

[0209] In this embodiment, each LCD 114 includes a combiner unit 1121 and a PWM controller 1123. The combiner unit 1121, which may be implemented in hardware and / or software, is configured to modulate or scale a normalized reference signal Vrn of the control information using a modulation index Mi of the control information. In some embodiments, the combiner unit 1121 is a software module of the LCD 114. The combiner unit 1121 outputs the modulated reference signal to the PWM controller 1123.

[0210] The PWM controller 1123, which may be implemented in hardware and / or software, generates switching signals for the switches of the converter 202 using PWM techniques (e.g., the PWM techniques described above). The PWM controller 1123 may be configured to generate carrier signals using a PWM counter. The PWM controller 1123 may use the PWM counter to provide appropriate phase shifts between carrier signals for the switches of the converter 202.

[0211] LCD 114 may decode the control information data element to obtain a normalized reference signal Vrn, a modulation index Mi, and an identifier. A combiner unit 1121 modulates or scales the normalized reference signal Vrn using an assigned modulation index Mi (e.g., a modulation index Mi received in a control information data element), the control information data element including an identifier for a module 108 that includes (or is communicatively coupled to) LCD 114. When LCD 114 receives a control information data element, LCD 114 may determine whether the identifier included in the control information data element matches the identifier for its module 108. If it matches, the combiner unit 1121 scales the normalized reference signal Vrn of the received control information data element using the modulation index Mi. If it does not match, the combiner unit 1121 scales the normalized reference signal Vrn of the received control information data element using the most recently received modulation index Mi for the module 108 that includes (or is communicatively coupled to) LCD 114.

[0212] For example, when the LCD 114 of the module 108-1 in the array 700-PA receives a control information data element including an identifier identifying the module 108-1 in the array 700-PA, the control information data element includes a normalized reference signal VrnPA for the array 700-PA and a modulation index MiPA1 for the module 108-1 in the array 700-PA. In this example, the LCD 114 of the module 108-1 in the array 700-PA scales the normalized reference signal VrnPA using this modulation index MiPA1. The next control information data element may include an identifier identifying the module 108-2 in the array 700-PA, the control information data element including a normalized reference signal VrnPA for the array 700-PA and a modulation index MiPA2 for the module 108-2 in the array 700-PA. The module 108 - 1 in the array 700 -PA uses the modulation index MiPA1 from the previously received control information data element to scale the newly received normalized reference signal VrnPA instead of using the modulation index MiPA2 to scale the normalized reference signal VrnPA.

[0213] When LCD 114 receives a control information data element including an identifier for its module 108 and a modulation index Mi, LCD 114 may store the modulation index Mi for use in scaling each received reference signal received by LCD 114 until receiving the next modulation index Mi for LCD 114. For example, LCD 114 of module 108-1 in array 700-PA may receive a control information data element having a normalized reference signal VrnA and a modulation index MiPA1. Combiner unit 1121 may scale the normalized reference signal VrnA using the modulation index MiPA1, and PWM controller 1123 may control the switch circuitry of module 108-1 in array 700-PA using the scaled reference signal. LCD 114 of module 108-1 in array 700-PA may also store the modulation index MiPA1. The next control information data element received by LCD 114 of module 108-1 in array 700-PA may include the updated normalized reference signal VrnA and modulation index MiPA1 for module 108-2 in array 700-PA, and may not include the modulation index MiPA1 for module 108-1 in array 700-PA. Combiner unit 1121 of module 108-1 in array 700-PA may scale reference signal VrnPA using the previously received and stored modulation index MiPA1. Combiner unit 1121 of module 108-1 in array 700-PA may continue to do this until another modulation index MiPA1 is received in a control information data element including an identifier for module 108-1 in array 700-PA.

[0214] The combiner unit 1121 of each LCD 114 can use its modulation index Mi to scale the normalized reference signal Vrn, for example, by determining the product of the normalized reference signal Vrn and its modulation index MiPA1. The PWM controller 1123 of each LCD 114 can then operate the switching circuitry of its converter 202 (e.g., generate a control signal for each switch) based on the scaled reference signal using PWM or hysteresis techniques, as described in detail above. In this way, a modulation index Mi similar to the modulation index Mi described above can be used to control the PWM switching signal provided to the power converter switching circuitry, and thus the operation of the regulation module 108. The output of each converter 202 can be connected together to provide an accumulated output signal to a load such as a fixed or mobile application.

[0215] As described above, for example, with reference to Figure 8C and 8D, the carrier signal for each module 108 in the array 700 is phase shifted to generate a multi-level output voltage. To ensure proper phase shifting of the carrier signal between modules 108, the PWM counters of the PWM controllers 1123 of the modules 108 can be synchronized using the synchronization techniques described herein. In general, when a PWM synchronization event is detected, the PWM controller 1123 can reset its PWM counter to restart the carrier signal generated by the PWM controller 1123.

[0216] In some embodiments, the PWM controller 1123 is synchronized using a synchronization signal sent from the MCD 112 via paths 1141-1 to 1141-3. In such embodiments, the MCD 112 includes a synchronization interface 1140 configured to generate the synchronization signal. In some embodiments, as described in more detail below, the PWM controller 1123 is synchronized using a data loss event. In such embodiments, the MCD 112 may or may not include the synchronization interface 1140.

[0217] The communication paths 1141-1 to 1141-3 may pass through a desired unidirectional or bidirectional physical layer, which may be, for example, an RS-485 or Ethernet physical layer. The synchronization interface 1140 of the MCD 112 and the corresponding synchronization interface 1743 of the LCD 114 ( Fig.17 ) may each include a corresponding interface, such as a differential half-duplex serial synchronous interface for RS-485 or Ethernet transceivers. Communication paths 1141-1 through 1141-3 may include twisted pair wiring that connects the synchronization interface 1140 of the MCD 112 to the synchronization interface 1743 of the LCD 114 of each array 700-PA, 700-PB, and 700-PC. In other embodiments, the wiring may be optical fiber or a conductive arrangement other than twisted pair.

[0218] The paths and links 105, 106, 115, 116, 118, 1108, 1141, 1213 discussed herein ( Fig.12 ) and 2501 to 2508 ( Fig.25A ) can be single-pipe or multi-pipe paths or links, and different paths or links (e.g., 115 and 1141) between the same entity (e.g., MCD 112 and LCD 114) can be merged or combined on a single path. To the extent that embodiments of the present invention are described with reference to the RS-485 standard for ease of description, those embodiments are not limited to use with RS-485 only, but also apply to other forms of communication, whether standardized or non-standardized.

[0219] The synchronization signal can be used for a number of purposes. For example, the synchronization signal can be used to synchronize the PWM controller 1123, synchronize the reception of control information packets, and / or wake up the LCD 114 when the LCD 114 is in a sleep mode.

[0220] In general, the synchronization signal can be a modulated signal, such as a modulated square wave signal. MCD 112 can adjust the pulse width in the pulse sequence in the synchronization signal and / or the frequency of the synchronization signal to trigger a synchronization event. MCD 112 can be configured to use different types of modulation, for example, based on the physical layer used for paths 1141-1 to 1141-3 and / or the type of isolation used to isolate interfaces 1140 and 1743 from paths 1141-1 to 1141-3. Exemplary synchronization techniques are described in more detail below.

[0221] Fig.12 is a block diagram depicting an exemplary embodiment of a single-phase energy system 100. The system 100 includes an external control device 104, an MCD 112, and an array 700 of cascaded modules 108 (108-1 to 108-5). Although this exemplary array 700 includes five modules 108, other suitable numbers of modules 108 may be used.

[0222] Each module 108 includes an LCD 114, a converter 202, batteries 206-1 and 206-2, and an internal communication path 118. Although two batteries 206-1 are shown, the module 108 may include other numbers of batteries 206. The internal communication path includes a communication path 118-1 that communicatively couples the converter 202 and the battery 206-1, and a communication path 118-2 that communicatively couples the batteries 206-1 and 206-2. The communication path 118-1, which may be an RS-485 physical layer or another appropriate path, enables the LCD 114 to obtain status information for the battery. Although batteries 206 are shown in this example, other energy sources may be used, as described above.

[0223] As described above, LCD 114 can use modulation index Mi to scale the normalized reference signal Vrn, and use PWM techniques to operate the circuit system of converter 202 based on the scaled reference signal. Each converter 202 can be configured to convert the DC signal from battery 206-1 and 206-2 into an AC signal. The combined AC signal of module 108-1 to 108-5 is output to load interface 1260, which can be electrically connected to a load. In some embodiments, load interface 1260 is a terminal block where a conductor can be connected.

[0224] The external control device 104 enables an operator to monitor and control the operation of one or more loads, including the load connected to the load interface 1260. This may include controlling when power is provided to the load and how much power is provided to the load. The external control device 104 may provide an interactive interface, such as a graphical user interface (GUI), that enables an operator to monitor and control the power to the load.

[0225] The external control device 104 is communicatively coupled to the MCD 112 by way of a communication path or link 105. In some embodiments, this communication path 105 may be implemented using a Modbus protocol, a Profibus protocol, or another suitable communication protocol. The external control device 104 may provide power control information to the MCD 112 via the communication path 105. This power control information may include, for example, a target voltage level, a target current level, a target AC frequency, a target phase, and / or other suitable characteristics of a target AC voltage waveform for the load.

[0226] The MCD 112 controls the modules 108-1 to 108-5 to generate an output AC waveform to the load interface 1260 based on the power control information received from the external control device 104, the state information 160 for the modules 108-1 to 108-5, and the characteristics of the AC waveform output by the modules 108-1 to 108-5 received from the coupling module 1212. Because the system 100 includes a single array 700 for a single phase, the MCD 112 uses intra-phase balancing to balance the modules 1221, but does not use inter-array balancing. As described above, the MCD 1210 can use information and balancing techniques to generate a normalized reference signal Vrn and a modulation index Mi for the modules 108-1 to 108-5.

[0227] The system 100 includes a communication path 115 that communicatively couples the MCD 112 to the LCD 114 of each module 108. The MCD 112 may send control information data elements to the LCD 114 via the communication path 115. As described above, the control information data elements may include a normalized reference signal, a modulation index Mi for the module 108, and an identifier for the module 108. As described above, the communication path 115 may be a serial communication path that couples to the MCD 112 and a respective communication interface of the LCD 114 of each module 108-1 to 108-5 in the array 700.

[0228] The MCD 112 and LCD 114 of each module 108-1 to 108-5 may also communicate via a bidirectional communication path 1108 that communicatively couples the MCD 112 to the LCD 114 of each module 108. As described above, the communication path 1108 enables the MCD 112 and LCD 114 to exchange information, such as status information 160 for each module 108-1 to 108-5.

[0229] The system 100 also includes a communication path 1141 that communicatively couples the MCD 112 to the LCD 114 of each module 108. The MCD 112 may send synchronization signals to the LCD 114 through the communication path 1141 as described above.

[0230] Each embodiment of the system 100 described herein may include one or more coupling modules 1212. Each system embodiment may have a single coupling module. The coupling module 1212 is connected in series with the output of the converter 202 so that the coupling module 1212 can measure the characteristics of the AC waveform output by the module 1221. These characteristics may include, for example, the voltage level and current level of the AC waveform. Figures 16A to 16B An exemplary coupling module is depicted in and described below.

[0231] The coupling module 1212 is communicatively coupled to the MCD 112 using a communication path or link 1213. The coupling module 1212 provides the measured characteristics to the MCD 112 via the communication path 1213. In some implementations, the communication path 1213 is a high speed serial interface (HSSI). The HSSI may include parallel data lines or differential pairs that enable data transfer rates of 1 to 2+ Gigabits per second (Gbps).

[0232] Fig.13 is a block diagram depicting an exemplary embodiment of a phased energy system 100. The system 100 and Fig.12 The system 100 of is different in that there are two arrays 700-PA and 700-PB each including a number "N" of modules 108 (108-1 to 108-N) for providing a three-wire split-phase AC output to a load interface 1260 connectable to a load. The load interface 1260 may include terminals that make a first AC system output (L1), a second AC system output (L2), and a neutral system output (N) electrically available to the load.

[0233] Each module 108 may include an LCD 114, a converter 202, batteries 206-1 and 206-2, and the internal communication paths described above. The AC outputs of arrays 700-PA and 700-PB may be the same voltage (e.g., 120V), but the AC output of array 700-PA may be 180 degrees out of phase with respect to the AC output of array 700-N. This may produce an AC output signal measured between system output L1 and system output L2 that is twice the magnitude of the AC output signal from each array taken individually (e.g., between L1 and N). All embodiments of system 100 described herein may optionally be implemented in a split-phase topology.

[0234] The system 100 includes a coupling module 1212 (e.g., coupling modules 1212-1 and 1212-2). The MCD 112 controls the module 108 to generate a split-phase AC waveform and output it to a load interface 1260 based on power control information received from the external control device 104, state information 160 for the module 108, and characteristics of the AC voltage waveform output by the module 108 received from the coupling modules 1212-1 and 1212-2. Because this system 100 includes multiple arrays 700-PA and 700-PB for split-phase power conversion, the MCD 112 can be configured to balance the module 108 using intra-phase balancing and / or using inter-phase balancing. As described above, the MCD 112 can use information and balancing techniques to generate a normalized reference signal Vrn and a modulation index Mi for the module 108.

[0235] The system includes communication paths 115, such as communication paths 115-1 and 115-2. Communication path 115-1 communicatively couples MCD 112 to LCD 114 of each module 108 in array 700-PA. Similarly, communication path 115-2 communicatively couples MCD 112 to LCD 114 of each module 108 in array 700-PB.

[0236] The MCD 112 may send control information data elements to the LCDs 114 of the modules 108 in the array 700-PA via the communication path 115-1. Similarly, the MCD 112 may send control information data elements to the LCDs 114 of the modules 108 in the array 700-PB via the communication path 115-2. As described above, the control information data elements may include a normalized reference signal Vrn, a modulation index Mi for the module 108, and an identifier for the module 108. As described above, the communication path 115 may be a serial communication path that couples to the MCD 112 and the LCD 114 of each module 108.

[0237] By using two different communication paths 115-1 and 115-2, the MCD 112 may send a single normalized reference signal to each module 108 in the array 700-PA via communication path 115-1 and a single normalized reference signal to each module 108 in the array 700-PB via communication path 115-2. Because the normalized reference signals for different arrays may be different, e.g., by having at least different phase angles, this may reduce the amount of data sent along each communication path 115-1 and 115-2, and may increase the speed at which updated normalized reference signals are sent to each module 108. For example, the MCD 112 does not have to include both normalized reference signals in the same data frame, which would increase the size of the data frame, or if the MCD 112 alternates between the two reference signals, which would reduce the speed at which control information is sent to the modules 108.

[0238] The MCD 112 and LCD 114 of each module 108 may also communicate via a bidirectional communication path that communicatively couples the MCD 112 to the LCD 114 of each module 108. Figures 11A to 11B The two arrays 700-PA and 700-PB may share a common bidirectional communication path or have separate bidirectional communication paths, such as a bidirectional communication path that communicatively couples the LCDs 114 of the modules 108 in the array 700-PA to the MCD 112 and a bidirectional communication path that communicatively couples the LCDs 114 of the modules 108 in the array 700-PB to the MCD 112.

[0239] The system 100 may also include a communication path 1141-1 that communicatively couples the MCD 112 to the LCD 114 of each module 108 in the array 700-PA. Similarly, the system 100 also includes a communication path 1141-2 that communicatively couples the MCD 112 to each module 108 in the array 700-PB. As described above, the MCD 112 may send a synchronization signal to the LCD 114 through the communication path 1141.

[0240] The coupling module 1212-1 is connected in series with the output of the converter 202 of the module 108 in the array 700-PA so that the coupling module 1212-1 can measure the characteristics of the AC waveform output by the module 108 in the array 700-PA. These characteristics may include, for example, the voltage level and current level of the AC waveform. The coupling module 1212-1 is communicatively coupled to the MCD 112 using the communication path 1213. The coupling module 1212-1 provides the monitored characteristics to the MCD 112 through the communication path 1213.

[0241] The coupling module 1212-1 is connected in series with the output of the converter 202 of the module 108 in the array 700-PB so that the coupling module 1212-2 can measure the characteristics of the AC waveform output by the module 108 in the array 700-PB. These characteristics may include, for example, the voltage level and current level of the AC waveform. Although not shown, the coupling module 1212-2 can be connected to the MCD 112 in the same manner as the coupling module 1212-1, for example, using the communication path 1213.

[0242] Embodiments of the system 100 described herein may include a single coupling module 1212 electrically connected to both arrays 700-PA and 700-PB, or may include a plurality of discrete coupling modules 1212, one for each array 700-A and 700-B. In this example, the output of the converter 202 of each array 700-PA and 700-PB may be individually connected in series with a coupling module 1212 so that the coupling module 1212 may measure characteristics of the AC waveform output by each array 700-PA and 700-PB and provide the measured characteristics to the MCD 112.

[0243] Fig.14 is a block diagram depicting an exemplary embodiment of a three-phase energy system 100. The system 100 and Fig.12 System 100 and Fig.13 The system 100 differs in having three arrays 700-PA, 700-PB, and 700-PC, each including a number "N" of modules 108 (108-1 through 108-N) for providing a four-wire three-phase AC output to a load interface 1260 connectable to a load.

[0244] Each module 108 may include LCD 114, converter 202, batteries 206-1 and 206-2, and the internal interfaces described above.The AC output of each array may be 120 degrees out of phase with respect to each other array.

[0245] The system 100 includes a coupling module 1212 (e.g., coupling modules 1212-1, 1212-2, and 1212-3). The MCD 112 controls the module 108 to generate a three-phase AC waveform and output it to a load interface 1260 based on power control information received from the external control device 104, state information 160 for the module 108, and characteristics of the AC voltage waveform output by the module 108 received from the coupling modules 1212-1, 1212-2, and 1212-3. Because this system 100 includes multiple arrays 700-PA, 700-PB, and 700-PC for three-phase power conversion, the MCD 112 can be configured to balance the module 108 using intra-phase balancing and / or using inter-phase balancing. As described above, the MCD 112 can use information and balancing techniques to generate a normalized reference signal Vrn and a modulation index Mi for the module 108.

[0246] The system 100 includes communication paths 115, such as communication paths 115-1, 115-2, and 115-3. Communication path 115-1 communicatively couples the MCD 112 to the LCD 114 of each module 108 in the array 700-PA. Similarly, communication path 115-2 communicatively couples the MCD 112 to the LCD 114 of each module 108 in the array 700-PB, and communication path 115-3 communicatively couples the MCD 112 to the LCD 114 of each module 108 in the array 700-PC.

[0247] The MCD 112 may send control information data elements to the LCDs 114 of the modules 108 in the array 700-PA via the communication path 115-1. Similarly, the MCD 112 may send control information data elements to the LCDs 114 of the modules 108 in the array 700-PB via the communication path 115-2, and to the LCDs 114 of the modules 108 in the array 700-PC via the communication path 115-3. As described above, the control information data elements may include a normalized reference signal Vrn, a modulation index Mi for the module 108, and an identifier for the module 108. As described above, the communication path 115 may be a serial interface that is coupled to the MCD 112 and the LCD 114 of each module 108.

[0248] The MCD 112 and the LCD 114 of each module 108 may also communicate via a bidirectional communication path that communicatively couples the MCD 112 to the LCD 114 of each module 108. Figures 11A to 11BThe arrays 700-PA, 700-PB, and 700-PC may share a common bidirectional communication path, or may have separate bidirectional communication paths, such as a bidirectional communication path that communicatively couples the LCDs 114 of the modules 108 in the array 700-PA to the MCD 112, a bidirectional communication path that communicatively couples the LCDs 114 of the modules 108 in the array 700-PB to the MCD 112, and a bidirectional communication path that communicatively couples the LCDs 114 of the modules 108 in the array 700-PC to the MCD 112.

[0249] The system 100 also includes a communication path 1141-1 that communicatively couples the MCD 112 to the LCD 114 of each module 108 in the array 700-PA. Similarly, the system 100 includes a communication path 1141-2 that communicatively couples the MCD 112 to each module 108 in the array 700-PB and a communication path 1141-3 that communicatively couples the MCD 112 to each module 108 in the array 700-PC. As described above, the MCD 112 may send synchronization signals to the LCD 114 via the communication path 1141.

[0250] The coupling module 1212-1 is connected in series with the output of the converter 202 of the module 108 in the array 700-PA so that the coupling module 1212-1 can measure the characteristics of the AC waveform output by the module 108 in the array 700-PA. These characteristics may include, for example, the voltage level and current level of the AC waveform. The coupling module 1212-1 is communicatively coupled to the MCD 112 using the communication path 1213. The coupling module 1212-1 provides the monitored characteristics to the MCD 112 through the communication path 1213.

[0251] The coupling module 1212-2 is connected in series with the output of the converter 202 of the module 108 in the array 700-PB so that the coupling module 1212-2 can measure the characteristics of the AC waveform output by the module 108 in the array 700-PB. These characteristics may include, for example, the voltage level and current level of the AC waveform. Although not shown, the coupling module 1212-2 can be connected to the MCD 112 in the same manner as the coupling module 1212-1, for example, using the communication path 1213.

[0252] The coupling module 1212-3 is connected in series with the output of the converter 202 of the module 108 in the array 700-PC so that the coupling module 1212-3 can measure the characteristics of the AC waveform output by the module 108 in the array 700-PC. These characteristics may include, for example, the voltage level and current level of the AC waveform. Although not shown, the coupling module 1212-3 can be connected to the MCD 112 in the same manner as the coupling module 1212-1, for example, using the communication path 1213.

[0253] In some embodiments, the three-phase energy system 100 may include a single coupling module 1212 for all three arrays 700-PA, 700-PB, and 700-PC. In this example, the outputs of the converters 202 of each array 700-PA, 700-PB, and 700-PC may each be individually connected in series with the coupling module 1212 so that the coupling module 1212 can measure the characteristics of the AC waveform output by each array 700-PA, 700-PB, and 700-PC and provide the measured characteristics to the MCD 112.

[0254] Fig.15 is a block diagram depicting an interface of an exemplary embodiment of the MCD 112. The MCD 112 may be used to implement the MCD of any of the systems 100 described herein. The MCD 112 also includes Fig.15 Components not shown in FIG. 1 , such as controller 900, controller 950, and / or other components described above. Fig.15 Specific types of interfaces are shown in and described below, but other types of suitable interfaces may also be used.

[0255] The MCD 112 includes a control interface 1510, which includes an external control device interface 1511 (e.g., a high level control system (HLCS) transceiver), a local computer interface 1512 (e.g., a USB-COM transceiver), and an Internet interface 1513 (e.g., an Ethernet transceiver). The external control device interface 1511 can be configured to communicate with the external control device 104 via the path 105. In one example, the external control device interface 1511 can be implemented as an RS-485 serial interface for coupling to a bus that is coupled to the site controller. Other suitable interfaces can be used. The external control device 104 can provide power control information to the MCD 112 via the external control device interface 1511.

[0256] The local computer interface 1512 may be configured to communicate with one or more computers, for example, via a USB cable. The Internet interface 1513 is configured to connect the MCD 112 to a remote system, for example, via the Internet or another network. The MCD 112 may use an Ethernet transceiver to obtain firmware updates, retrieve log information, etc. from a remote system.

[0257] The MCD 112 includes discrete inputs 1520. The discrete inputs 1520 receive feedback from the coupling module 1212. In this example, the discrete inputs 1520 include a ground fault status input for receiving an indication of a ground fault (at GND_SAFE) or another type of fault, such as a power fault (at +24V_SAFE). In the event of a fault, the MCD 112 may instruct or cause the system 100 to terminate operation and shut down. The discrete inputs may also include a coupling module status input for indicating whether a grid contactor connecting the system 100 to the grid is closed and whether a load contactor connecting the system 100 to the load is closed.

[0258] The MCD 112 includes discrete outputs 1530. The discrete outputs 1530 include one or more outputs to a grid contactor for controlling a grid contactor switch (e.g., an electromechanical relay) that selectively connects to and disconnects from the grid, and one or more outputs to a load contactor for controlling a load contactor switch (e.g., an electromechanical relay) that selectively connects to and disconnects from the load. The grid contactor switch and the load contactor switch can be positioned within the system 100 as desired, such as in the coupling module 1212.

[0259] MCD 112 includes a serial interface 1540, such as a HSSI, configured to provide a fast interface for receiving signals from coupling module 1212. For example, coupling module 1212 may digitize an analog signal and send it to MCD 112 via a serial bus coupled to HSSI 1540.

[0260] The MCD 112 includes an analog input 1550 configured to receive as analog input the analog output from the coupling module 1212. The analog input may include sensed voltage and current measurements output by each array 700 for the various phases.

[0261] As described above, the coupling module 1212 may measure characteristics of the AC waveform output by the module 108. These characteristics may include, for example, the voltage level and the current level of the AC waveform. The coupling module 1212 may provide the characteristics for each phase in analog form to a corresponding analog input and / or digitally to the serial interface 1540, which may be implemented as an HSSI as described above.

[0262] The MCD 112 includes a digital interface 1560 for communicating with the LCD 114 of the module 108. The digital interface 1560 can be bidirectional and / or unidirectional, and can communicate information according to various standardized or custom protocols. Here, the interface 1560 includes a bidirectional CAN protocol transceiver 1562 for each array 700 of the cascaded module 108 (e.g., for each phase of the output AC signal). For example, the digital interface 1560 includes a CAN transceiver A 1562-1 for the array 700-PA, a CAN transceiver B 1562-2 for the array 700-PB, and a CAN transceiver C 1562-3 for the array 700-PC. The CAN transceiver 1562 is configured to communicate via a CAN bus that couples the CAN transceiver 1562 to the CAN transceiver of the LCD.

[0263] The CAN transceiver 1562 directly enables bidirectional data exchange between the MCD 12 and the LCD 114 and between the LCDs 114. For example, the LCD 114 can send status information 160 to the MCD 112 via the CAN bus. If a module 108 detects a fault, the LCD 114 can notify the MCD 112, and the MCD 112 can instruct the faulty module to terminate operation. The CAN interface also enables communication between any LCD 114 and any other LCD 114. This can be useful if one of the LCDs 114 detects a fault but there is also a fault in the MCD 112 such that the MCD 112 is unable to take action in response to the fault. In this case, the fault command sent from the faulty LCD 114 will be received by the other operational LCDs 114, and these LCDs 114 can take safety actions, such as disconnecting the converter 202 from the AC line. Using a CAN interface, or other protocol with similar capabilities, enables the MCD 112 to be bypassed, and the LCD 114 can instruct the other LCDs 114 in the array 700 to, for example, turn off. Although the MCD 112 includes a CAN transceiver for each array, the MCD 112 can communicate with the LCDs 114 of multiple arrays using a single CAN transceiver over a single CAN bus coupled to the MCD 112 and each LCD 114 in the multiple arrays. The number of CAN buses can vary, for example, based on the bandwidth of the interface and the data sent across the interface.

[0264] The digital interface 1560 also includes a serial transceiver 1564, such as an RS-485 transceiver, which is configured to couple to a serial bus, such as a twisted pair. The serial transceiver 1564 can be implemented as, for example, an RS-485 transceiver and / or an Ethernet transceiver.

[0265] The MCD 112 uses a serial transceiver 1564 to send control information to the LCD 114. As described above, the control information may include a reference signal, a modulation index, and an identifier for a normalization of the module. The MCD 112 includes a serial transceiver 1564 for each cascaded module array (e.g., for each phase of the output AC signal). Specifically, the MCD 112 includes a serial transceiver A 1564-1 for sending control information to the LCD 114 of the module 108 in array A, a serial transceiver B 1564-2 for sending control information to the LCD 114 of the module 108 in array B, and a serial transceiver C 1564-3 for sending control information to the LCD 114 of the module 108 in array C.

[0266] The digital interface 1560 also includes a wake-up interface 1565. The wake-up interface 1565 may be used to send a wake-up signal to the LCD 114 to wake up the LCD 114 from the sleep operation mode. For example, the MCD 112 may send a command instructing the LCD 114 to enter the sleep operation mode through the interface 1565. To wake up the LCD 114 from the sleep operation mode, the MCD 112 may send a wake-up signal to each LCD 114 using the wake-up interface 1565.

[0267] The MCD 112 includes an analog-to-digital converter (ADC) that converts analog signals into digital signals. The MCD 112 includes a light emitting diode (LED) indicator 1572 that indicates information about the MCD 112 and / or a system 110 including the MCD 112, such as status information, fault information, etc. The MCD 112 also includes a display 1573 that displays information about the MCD 112 and / or the system 110 and / or enables a user to provide information or commands to the MCD 112. For example, the display 1573 may include a touch screen or other input device that enables a user to interact with the MCD 112.

[0268] MCD 112 includes volatile memory 1574 (e.g., DRAM) and non-volatile memory (e.g., flash memory, hard drive, etc.) 1575. Volatile memory 1574 can be used to execute instructions and store data currently in use, while non-volatile memory 1575 can be used to store energy independent information, such as logs.

[0269] The MCD 112 includes a control device 1576, which may be in the form of a processor, a microcontroller, a field programmable gate array (FPGA), or other suitable type of control device. The control device 1576 may execute software that performs the various functions of the MCD 112 described herein. For example, the control device 1576 may implement the controller 900 and / or the controller 950.

[0270] MCD 112 includes a programming interface 1577. Programming interface 1577 enables a user to program and / or debug MCD 112. In some embodiments, programming interface 1577 includes a Joint Test Action Group (JTAG) interface.

[0271] The MCD 112 includes one or more power supplies 1578 for powering the various hardware components of the MCD 112. The MCD 112 also includes an internal bus 1590 that communicatively couples the various hardware components of the MCD 112.

[0272] Figures 16A to 16B is a block diagram depicting exemplary components of coupling module 1212. Coupling module 1212 can be used to implement the coupling modules described herein.

[0273] refer to Fig.16A , coupling module 1212 includes a voltage and current detector 1605 for each of one or more phases. In this example, coupling module 1212 includes a phase A voltage and current detector 1605-1, a phase B voltage and current detector 1605-2, and a phase C voltage and current detector 1605-3. Each voltage and current detector 1605 may include a voltage sensor and a current sensor for measuring the voltage and current of the AC waveform generated by converter 202 for its phase.

[0274] Each voltage and current detector 1605 can provide its voltage and current measurements to the MCD 112 via the communication path 1213. The communication path 1212 can include a digital signal path and / or an analog signal path. When the communication path 1212 is a digital signal path, the coupling module 1212 can include an ADC to convert the analog measurements to digital signals. The coupling module 1212 can provide the digital signals to the serial interface 1540 ( Fig.15 ).

[0275] When the communication path 1213 includes an analog signal path, the communication path 1213 may include a corresponding conductor for each measurement. The coupling module 1212 may provide the analog measurement to the analog input 1550 ( Fig.15 ).

[0276] The coupling module 1211 includes a grid controller 1670 and a grid state module 1675. The grid controller 1670 can operate a grid switch that selectively connects the system 100 to the grid. The grid state module 1675 can receive a state signal indicating whether the grid switch is open or closed. For example, the grid state module 1675 can be coupled to a contactor of the grid switch, which opens and closes with the grid switch.

[0277] The coupling module 1211 includes a load controller 1680 and a load state module 1685. The load controller 1680 can operate a load switch that selectively connects the system 100 to the load. The load state module 1685 can receive a state signal indicating whether the load switch is open or closed. For example, the load state module 1685 can be coupled to a contactor of the load switch, which opens and closes with the load switch.

[0278] Fig. 16B Additional details of the internal components of an exemplary coupling module 1212 are provided. The coupling module 1212 includes a sensor 1611 for each phase of the three-phase AC signal. The sensors 1611-1 to 1611-3 can be parts of the detectors 1605-1 to 1605-3, respectively. Each set of sensors 1611-1 to 1611-3 can include: a voltage sensor that measures the voltage of its phase; and a current sensor that measures the current of its phase and provides the measured values ​​to a corresponding interface 1612-1 to 1612-3, which can include a shielded RJ-45 jack. The interfaces 1612-1 to 1612-3 can be coupled to corresponding cables that connect the coupling module 1212 to a network, which is also coupled to the MCD 1212. In this way, the coupling module 1212 can provide the measured voltage and current to the MCD 1212. In some embodiments, the coupling module 1212 provides the measured signals to the MCD 1212 as differential analog signals. In some implementations, the coupling module 1212 uses HSSI to provide the measured signal to the MCD 1212. Other suitable communication interfaces may also be used.

[0279] The coupling module 1212 includes a grid contactor status switch 1676, which is part of or implements the grid status module 1675. When the grid switch is closed, the grid contactor status switch 1676 may also be closed to indicate that the grid switch is closed. The coupling module 1212 also includes a load contactor status switch 1686, which is part of or implements the load status module 1685. When the load switch is closed, the load contactor status switch 1686 may also be closed to indicate that the load switch is closed.

[0280] The coupling module 1212 also includes a grid relay 1671, which is part of or implements the grid controller 1670. The coupling module 1212 can close the grid relay 1671 to energize the coil of the grid switch to close the grid switch. The coupling module 1211 can open the grid relay 1671 to de-energize the coil of the grid switch to open the grid switch.

[0281] The coupling module 1212 also includes a load relay 1681, which is part of or implements the load controller 1680. The coupling module 1212 can close the load relay 1681 to energize the coil of the load switch to close the load switch. The coupling module 1211 can open the load relay 1681 to de-energize the coil of the load switch to open the load switch.

[0282] The coupling module 1212 also includes a connector 1660 for connecting conductors of the coupling module 1212 and a ground fault interrupter (GFI) 1690 for detecting ground faults.

[0283] The MCD 1212 may send a command to close the grid relay 1671 or the load relay 1681 to the coupling module 1212 in a manner to minimize overcurrent of the energy storage system (ESS) due to the asynchronous AC line voltage and the ESS voltage. The MCD 1212 may send a command to open the grid relay 1671 and the load relay 1681 due to islanding detection or other fault detection signals, such as overvoltage, undervoltage, overcurrent, overtemperature, etc.

[0284] Fig.17 1 is a block diagram depicting an exemplary embodiment of LCD 114. LCD 114 may be used to implement the LCD 114 described herein. As described above, LCD 114 may be part of module 108, which includes energy source 206 (e.g., one or more batteries) and converter 202 in addition to LCD 114. Although Fig.17 Specific types of interfaces are shown in and described below, but other types of suitable interfaces may also be used.

[0285] The LCD 114 includes a BMS interface 1711 configured to communicate with a BMS 1710 that manages and / or monitors one or more batteries of the module's energy source. In some embodiments, the BMS interface 1711 includes a CAN controller that is coupled to a CAN bus that is also coupled to the BMS 1710. The BMS interface 1711 can receive battery status information 160 from the BMS 1710 via the CAN bus. The battery status information can include, for example, voltage, current, temperature, SOC, SOH, and depth of discharge (DOD).

[0286] LCD 114 includes a battery module controller 1713 that is configured to perform functions to protect the battery. For example, the battery module controller 1713 can be configured to receive battery status information and perform balancing between the batteries 206 of the module 108, and provide over-voltage, under-voltage, over-current, and under-current protection to the batteries 206 of the module 108.

[0287] LCD 114 includes a ConBatt interface 1721, which is configured to communicate with a ConBatt converter 1720. Conbatt interface 1721 may include an ADC controller, a PWM controller, and a GPIO controller, each of which is configured to communicate with ConBatt converter 1720 (e.g., a serial interface converter). The ADC controller may receive analog data from Conbatt converter 1720, convert the analog data into a digital format, and send the digital data to memory 122. Similar to Figures 6A to 6C The ConBatt converter 1720 can be a power converter and may also include a power switch gate driver and a DC link circuit.

[0288] LCD 114 includes a human machine interface (HMI) interface 1731 configured to communicate with an HMI 1730 of module 108. HMI 1730 may display status information 160 for module 108 and provide a user interface including interactive controls that enable an operator to control module 108 locally.

[0289] LCD 114 includes a CAN interface 1741 and a control interface 1742 configured to communicate with MCD 112. CAN interface 1741 may send status information 160 for module 108 to MCD 112, for example, via a CAN bus coupled to CAN interface 1742 and MCD 112. CAN controller 1741 may obtain status information 160 from memory 122 and send status information 160 to MCD 112 via the CAN bus.

[0290] The control interface 1742 may receive control information, for example, in the form of control information data elements, from the MCD 112 via a serial interface that includes a serial bus coupled to the control interface 1742 and the MCD 112. The control interface 1742 may receive the control information data elements and send the control information data elements to the memory 122 for storage. The control interface 1742 may be connected to a control information communication device that is configured to decode the control information data elements received from the MCD 112.

[0291] LCD 114 also includes a synchronization interface 1743 and a wake-up interface 1744 configured to receive a synchronization signal from MCD 112. As described in more detail below, the synchronization signal can be used to receive a control information packet and wake up LCD 114 from a sleep mode of operation. LCD 114 can be configured to monitor wake-up interface 1744 for a wake-up signal, for example, in the form of a synchronization signal, while in the sleep mode of operation. If a wake-up signal is detected, LCD 114 can activate other components of LCD 114 (e.g., each interface) and transition to an active mode of operation.

[0292] LCD 114 also includes a control device 1760, which may be in the form of a processor, microcontroller, FPGA, or other suitable type of control device. For example, control device 1760 may include processing circuit system 120. Control device 1760 may execute software that performs various functions of LCD 114 described herein.

[0293] LCD 114 also includes memory 122 , which may include volatile memory and / or non-volatile memory. LCD 114 also includes an internal bus 1590 that communicatively couples the various hardware components of LCD 114 .

[0294] Fig.18 1 is a flow chart depicting an exemplary embodiment of a method 1800 for sending a control information data element to a local control device and outputting a voltage waveform based on the control information data element. The method 1800 may be performed by an energy system that includes an MCD 112 and one or more arrays 700 of cascaded modules 108. For example, the method 1800 may be performed by any of the systems 100 having the MCD 112 and LCD 114 described in this document. As described above, each module 108 may include an energy source 206, a converter 202 including switching circuitry, and an LCD 114. Each module 108 in the array 700 may also have an identifier that identifies the module 108 and is unique within the array 700.

[0295] At step 1810, the MCD 112 receives an input signal including feedback signals and state information 160. The feedback signals for each array 700 may include voltage and current measurements (and / or other characteristics) made by a coupling module 1212 connected in series with the outputs of the converters 202 of the modules 108 in the array 700. As described above, the coupling module 1212 may measure the voltage and current of each phase and provide data indicative of the voltage and current of each phase to the MCD 112.

[0296] The status information 160 may include status information 160 for each module 108 in the array 700 of cascaded modules 108. As described above, the status information 160 may be information about one or more aspects, characteristics, or parameters of each module 108, such as the SOC of one or more energy sources of the module 108, the SOH of one or more energy sources 206 of the module 108, the temperature of one or more energy sources 206 or other components of the module 108, the capacity of one or more energy sources 206 of the module 108, the voltage of one or more energy sources 206 and / or other components of the module 108, the current of one or more energy sources 206 and / or other components of the module 108, the SOP, the SOE, and / or the presence or absence of a fault in any one or more of the components of the module 108.

[0297] The input signals may also include set points received by the MCD 112 from the external control device 104. These set points may include a target voltage and / or a target current to be output by each array 700, e.g., a target voltage and / or target current waveform. The set points may include other characteristics of the target output AC waveform, such as phase and / or frequency.

[0298] The MCD 112 is configured to receive the status information 160 via a bidirectional communication path between the MCD 112 and the LCD 114 of each module 108. For example, the bidirectional path may include a CAN bus or another suitable communication path.

[0299] At step 1820, the MCD 112 generates a normalized reference signal Vrn for the array 700 of cascaded modules 108 for each phase. As described above, the MCD 112 may include a controller 950 configured to generate a normalized reference signal Vrn based on a feedback signal. In some implementations, the MCD 112 may determine the difference between the set point and the feedback signal as a regulation error. The MCD 112 may generate a normalized reference signal Vrn to compensate for the error. For example, the MCD 112 may use a controller, such as a proportional integral (PI), a proportional-integral-derivative (PID), or other suitable controller, to adjust the normalized reference signal based on the error.

[0300] At step 1830, the MCD 112 generates a modulation index Mi for the modules 108 in the array 700 based on the state information 160. Step 1830 may be performed after, before, or simultaneously with step 1820. As described above, the modules 108 may be balanced relative to other modules 108 in the array 700 (intra-phase balance), and different arrays 700 may be balanced relative to each other array (inter-phase balance). The modulation index Mi for the modules 108 in the array 700 may be different. For example, if one of the modules 108 has a higher temperature than the other modules, the MCD 112 may reduce the output voltage level of the module 108 by reducing the modulation index Mi for the module 108. To ensure that the voltage level of the load remains at its target, the MCD 112 may also increase the modulation index Mi for one or more of the other modules 108 to increase the output voltage level of the module 108. Therefore, the modulation index Mi for at least one module 108 in the array 700 may be different from the modulation index Mi for at least one other module 108 in the array 700.

[0301] At step 1840, the MCD 112 sends a control information data element to the modules 108. The MCD 112 may send a different control information data element to each array 700 of the cascaded modules 108. The control information data element for the array 700 may include a normalized reference signal Vrn for all modules 108 in the array 700, a single identifier for a single module 108 in the array 700, and a modulation index Mi for the single module 108. As described above, the MCD 112 may cycle through the modules 108 in the array 700 in a sequence such that the MCD 112 provides the modulation index Mi for each module 108 in the array 700 once per cycle. During this cycle, the MCD 112 may select an identifier for one of the modules 108 and include the modulation index Mi and the identifier for the selected module 108 in the control information data element. Fig.19 An exemplary process for sending control information data elements to the LCD 114 is depicted in and described below. As described above, the MCD 112 may send the control information data elements to the LCD 114 via a serial communication path.

[0302] At step 1850, each LCD 114 scales the normalized reference signal Vrn using the modulation index Mi. The LCD 114 is configured to receive the control information data element and decode the data element to obtain the normalized reference signal Vrn, the modulation index Mi for one of the modules 108, and an identifier for one module 108, the identifier being encoded in the control information data element.

[0303] LCD 114 is also configured to determine whether the identifier of the control information data element includes an identifier of a module of LCD 114, for example, by comparing the identifiers. If they match, LCD 114 may scale the normalized reference signal Vrn of the control information data element using the modulation index Mi of the control information data element. If they do not match, LCD 114 may scale the normalized reference signal Vrn of the control information data element using the modulation index Mi of the most recently received control information data element, the most recently received control information data element including an identifier for the module 108 including LCD 114. As described above, scaling the normalized reference signal Vrn using the modulation index Mi may include multiplying the normalized reference signal Vrn by the modulation index Mi.

[0304] At step 1860, each LCD 114 uses the scaled reference signal to control the switching circuitry of the converter 202 of the module 108 that includes the LCD 114. The LCD 114 may operate the switching circuitry of its converter 202 (e.g., generate a control signal for each switch) using PWM or hysteresis techniques based on the scaled reference signal, as described in detail above. In this way, the modulation index Mi can be used to control the PWM switching signal provided to the power converter switching circuitry, and thus regulate the operation of the module 108.

[0305] The MCD 112 and LCD 114 may continuously perform the method 1800 to adjust the AC waveform output to the load connected to the output of the converter 202. For example, the MCD 112 may periodically send the control information data element based on a specified time period. In another example, the MCD 112 may send the control information data element whenever there is a change in the normalized reference signal Vrn or a change in one of the modulation indexes Mi.

[0306] Fig.19 is a flow chart depicting an exemplary embodiment of a method 1900 of sending a control information data element to the LCD 114. The method may be performed by the MCD 112.

[0307] At step 1910, the MCD 112 selects a module 108 in the array 700 of cascaded modules 108 to provide the modulation index Mi. As described above, the MCD 112 may select the modules 108 in a defined order (eg, from the first module 108 to the second module 108 to the third module 108, etc.).

[0308] At step 1920, the MCD 112 generates a control information data element including the modulation index Mi and the identifier for the selected module 108. The MCD 112 may encode the normalized reference signal Vrn for all modules 108 in the array 700, the modulation index Mi for the selected module 108, and the identifier for the selected module 108 in the control information data element.

[0309] At step 1930, the MCD 112 sends the control information data element to the modules 108 in the array 700, e.g., to all modules 108 in the array 700. The MCD 112 then returns to step 1910, where the MCD 112 selects another module 108 in the sequence. If the most recently sent control information data element contained the modulation index Mi and identifier for the last module 108 in the sequence, the MCD 112 may restart with the first module 108 in the sequence.

[0310] LCD 114 may employ various techniques for receiving control information data elements over the serial communication path. One technique involves determining when a complete control information data element has been received based on a duration that has elapsed since the first data packet was received and whether additional data packets have been received. Another technique involves MCD 112 sending a synchronization signal to LCD 114 indicating when a control information data element will arrive at LCD 114. Fig. 20 An exemplary method corresponding to the first technique is depicted in Fig. 22 An exemplary method corresponding to the second technique is depicted in .

[0311] Exemplary Techniques for Receiving Control Information

[0312] Fig. 20 is a flow chart depicting an exemplary embodiment of a method 2000 for receiving a control information data element. The method 2000 may be performed by an LCD 114 of an energy system that includes an MCD 112 and one or more arrays 700 of cascaded modules 108. For example, the method 2000 may be performed by any of the systems 100 having an MCD 112 and an LCD 114 as described in this document. As described above, each module 108 may include an energy source 206, a converter 202 including switching circuitry, and an LCD 114. Each module 108 in the array 700 may also have an identifier that identifies the module 108 and is unique within the array 700. Also refer to Fig.21 Describe Method 2000, Fig.21 is a diagram depicting an exemplary data flow 2100 .

[0313] At step 2010, the LCD 114 detects a first data unit on the communication interface connected to the communication path after at least a threshold duration since receiving a previous control information data element. As described above, the MCD 112 may periodically send a control information data element containing a normalized reference signal Vrn. The control information data element may also include a modulation index Mi and an identifier for the module 108 to which the modulation index Mi corresponds.

[0314] In some embodiments, each control information data element is a data frame including one or more data segments. In this example, each data unit may be a data segment of a data frame.

[0315] MCD 112 may periodically send control information data elements such that there is a time period between the end of reception of one control information data element and the transmission of the next control information data element. Fig.21 , there is a duration between each pair of consecutive data frames 2110, 2120, and 2130. This time period can be used by the LCD 114 to ensure that the control information data element is fully received and to determine that a newly received data unit after the time period is for a new control information data element. The threshold duration can be this time period or based on this time period. For example, if the MCD waits 150 microseconds after sending one control information data element before sending the next control information data element, the threshold duration can be a time period of 150 microseconds or less, such as 100 microseconds, 50 microseconds, or another appropriate duration. In some embodiments, the minimum threshold duration is used, for example, in Figures 11A to 11B The duration for sending one byte of data on the communication path 115.

[0316] As described above, each control information data element can have a common data size. In some embodiments, the control information data element can have a data size of four bytes. Other data sizes less than or greater than four bytes can also be used. Each data unit can be a byte, a data packet, or another part of the data that can be sent across the communication path at one time.

[0317] At step 2020, LCD 114 determines whether a new control information data element containing the detected data unit has been received. LCD 114 can be configured to determine whether a new control information data element has been received based on the duration that has elapsed since the first data unit was received and whether additional data units are received after the data reception time period of the new control information data element. LCD 114 can use steps 2021 to 2026 to determine whether a new control information data element has been received.

[0318] LCD 114 starts a timer in response to detecting the first data unit. The timer can be used for a data receiving time period, and the data receiving time period is used for a defined duration. For example, the timer can be a positive timer that counts from zero to the end of the defined duration, or a countdown timer that counts down from the defined duration to zero. In a specific example, the duration can be 70 microseconds. In this example, after starting the timer, the timer can count up from zero to 70 microseconds, or count down from 70 microseconds to zero.

[0319] The data reception time period may be based on an expected time period for receiving the entire control information data element.The expected time period may be based on the data size of each control information data element and the data rate of the communication path through which the control information data element is sent.

[0320] In some embodiments, the data reception time period is longer than the expected time period. Because data transmission may be delayed, for example, due to noise on the communication path, using a longer data reception time period can better ensure that the entire control information data element is received. In one example, the data reception time period can be based on the expected time period for the control information data element plus some additional time to receive one or two bytes of data. In another example, the data reception time period can be based on the expected time period for the control information data element plus an additional specified duration. Fig.21 , the exemplary data reception time period 2111 extends beyond the time required to receive a data frame 2110 containing a control information data element.

[0321] At step 2022, LCD 114 receives additional data units during the data reception period. As data units are received, LCD 114 may store each data unit locally.

[0322] At step 2023, the LCD 114 determines whether the data reception time period has expired (2023). For example, the LCD 114 may determine whether a counter has completed counting up or counting down based on the data reception time period.

[0323] If the data receiving time period has not expired, the LCD 114 returns to step 2022 to continue receiving additional data units. If the data receiving time period has expired, then in step 2024, the LCD 114 starts a timer for the post-receiving time period. The post-receiving time period may be immediately after the data receiving time period, and may have the same duration, a longer duration, or a shorter duration than the data receiving time period. Similar to the timer for the data receiving time period, the timer for the post-receiving time period may be a positive timer or a countdown timer. Referring to Figure 2100, an exemplary post-receiving time period 2112 is immediately after the data receiving time period 2111.

[0324] In some embodiments, for example, in the absence of a post-receive time period, a single timer may be used for a data element receive time period. In this example, a time period may have a duration longer than the expected duration for receiving a complete control information data element.

[0325] At step 2025, LCD 114 determines whether additional data units are received during the post-receive time period. LCD 114 may monitor for additional data units until the post-receive time period expires. If additional data units are received during the post-receive time period, LCD 114 may determine that the entire control information data element has not been received and return to step 2022 to receive additional data units. When the data receive time period has expired, LCD 114 may restart the post-receive time period for each additional data unit received during the post-receive time period until no additional data units are received during the post-receive time period.

[0326] If no additional data units are received during the post-receive time period, LCD 114 determines that a control information data element has been received in step 2026. In response, LCD 114 may process the control information data element in step 2030. This processing may include decoding the control information, scaling a normalized reference signal Vrn in the control information using a modulation index Mi, and operating the switching circuitry of converter 202 using the scaled reference signal.

[0327] LCD 114 may use the CRC bits to check for errors and / or correct the data in the control information data element before processing the control information data element. If the data cannot be corrected, LCD 114 may not use the control information in the control information data element to operate the switch circuit system. Instead, LCD 114 may use the previously received control information of the previously received control information data element to operate the switch circuit system. This ensures that there is no interruption in the operation of module 108 due to corrupted data.

[0328] Fig. 22is a flow chart depicting an exemplary embodiment of a method 2200 for receiving a control information data element using a synchronization signal. The method 2200 may be performed by an energy system that includes an MCD 112 and one or more arrays 700 of cascaded modules 108. For example, the method 2200 may be performed by any of the systems 100 described in this document. As described above, each module 108 may include an energy source 206, a converter 202 including a switching circuit system, and an LCD 114. Each module 108 in the array 700 may also have an identifier that identifies the module 108 and is unique within the array 700. Also refer to Fig.23 Describing method 2200, Fig.23 is a diagram depicting an exemplary data flow 2300 .

[0329] The MCD 112 may be communicatively coupled to each LCD 114 via a plurality of data communication paths. For example, the MCD 112 may be communicatively coupled to each LCD 114 using a unidirectional serial communication path through which the MCD 112 sends control information data elements, as described above. The MCD 112 may also be communicatively coupled to each LCD 114 using a synchronization signal bus. In some embodiments, the synchronization signal bus is implemented as a unidirectional serial communication path through which the MCD 112 sends synchronization signals to the LCD 114. For example, the synchronization signal bus may be implemented as a twisted pair that connects the MCD 112 to each LCD 114 in the array 700 of the cascade modules 108. Other protocols and buses may also be used for synchronization signals, such as digital communication paths. For simplicity, the method 2200 is described in terms of differential signals, which may be sent via a twisted pair bus or other appropriate communication paths.

[0330] At step 2210, the MCD 112 sends a synchronization signal to the LCD 114 of the modules 108 in the array 700 of cascaded modules 108. The synchronization signal indicates the start of the transmission of the control information data to the LCD 114. In some embodiments, the differential signal may have a high voltage difference, such as above a first threshold, to indicate the start of the transmission, or may have a low voltage difference, such as below a second threshold that is less than the first threshold, to indicate the end of the transmission. To indicate the start of the transmission, the MCD 112 may send the synchronization signal to the LCD 114 by increasing the voltage difference of the differential signal above the first threshold.

[0331] At step 2220, the MCD 112 sends a control information data element to the LCD 114 of the module 108 in the array 700. The control information data element may include one or more data packets within a data frame. The MCD 112 may send the control information data element at the same time as the synchronization signal or after a short delay (e.g., a delay in microseconds or milliseconds).

[0332] refer to Fig.23 , the leading edge of each synchronization signal 2310 - 1 to 2310 - 4 is aligned with the beginning of each frame 2320 - 1 to 2320 - 4 in which control information is sent from the MCD 112 to the LCD 114 .

[0333] At step 2230, LCD 114 detects a synchronization signal (2230). For example, LCD 114 may detect the synchronization signal based on a voltage difference of the differential signal. In this example, LCD 114 may compare the voltage level to a first threshold and determine that a synchronization signal is present when the voltage level satisfies the first threshold, e.g., by meeting or exceeding the first threshold.

[0334] At step 2240, the LCD 114 of each module 108 in the array 700 captures the control information data element. The LCD 114 may begin monitoring the control information in response to detecting the synchronization signal, and continue to monitor the control information until the synchronization signal is no longer present, for example, when the voltage difference of the differential signal is less than a second threshold. The LCD 114 may store the captured control information locally in a memory of the LCD.

[0335] LCD 114 may stop monitoring the control information after detecting that the synchronization signal is no longer present.After transmitting all control information, MCD 112 may remove the synchronization signal, for example, by reducing the voltage difference of the differential signal below a second threshold.

[0336] refer to Fig.23 , the falling edges of the synchronization signals 2310-1 to 2310-4 occur after the entire frames 2320-1 to 2320-4, respectively, have been sent from the MCD 112 to the LCD 114. In this example, there is a delay from the end of each frame to the falling edge of each synchronization signal. The MCD 112 may employ this delay to ensure that all data reaches each LCD 114 and is captured before the synchronization signal is removed.

[0337] At step 2250, the LCD 114 of each module 108 processes the control information data element. This processing may include decoding the control information, scaling the normalized reference signal Vrn in the control information using the modulation index Mi, and operating the switching circuitry of the converter 202 using the scaled reference signal.

[0338] LCD 114 may use the CRC bits to check for errors and / or correct the data in the control information data element before processing the control information data element. If the data cannot be corrected, LCD 114 may not use the control information in the control information data element to operate the switch circuit system. Instead, LCD 114 may use the previously received control information of the previously received control information data element to operate the switch circuit system. This ensures that there is no interruption in the operation of the module due to corrupted data.

[0339] The MCD 112 may also use the synchronization signal to, for example, "wake up" the LCD 114 from a sleep mode of operation of the LCD 114. In this way, the synchronization signal may be used for a dual purpose. For example, the LCD 114 may enter a sleep mode in which the LCD 114 saves power. In a specific example, when the electric vehicle is parked, the peripheral devices of the module (e.g., the power supply and the converter 202) are turned off, for example, by the MCD 112 and / or the LCD 114, and the LCD 114 may be configured to enter a sleep mode. In order to wake up the LCD 114 and start the peripheral devices, the MCD 112 may provide a trigger pulse on a wake-up interface (e.g., a wake-up pin) of the LCD 114. In order to use the synchronization signal for a dual purpose, the synchronization signal may also be connected to the wake-up pin to wake up the LCD 114 from the sleep mode. In response to the synchronization signal being applied to the wake-up pin, the LCD may start the peripheral devices and begin monitoring the control information.

[0340] Using a synchronization signal provides advantages over other methods. For example, using a synchronization signal provides a clear window for LCD 114 when control information is sent to LCD 114. With such a clear division, the dead period between frames can be reduced, which reduces delays in the system. This also enables an increase in the number of frames sent in the same time period, which provides a higher sampling rate for the reference signal.

[0341] Fig.24 is a flow chart depicting an exemplary embodiment of a method 2400 for waking up a local control device. The method 2400 may be performed by an energy system that includes an MCD 112 and one or more arrays 700 of cascaded modules 108. For example, the method 2400 may be performed by any of the systems 100 described in this document. As described above, each module 108 may include an energy source 206, a converter 202 including switching circuitry, and an LCD 114. Each module 108 in the array 700 may also have an identifier that identifies the module 108 and is unique within the array 700.

[0342] At step 2410, the MCD 112 determines to wake up the LCD 114. For example, the MCD of the electric vehicle can be configured to wake up each LCD 114 of the one or more arrays 700 of the module 108 when the user turns on the vehicle or initiates acceleration of the vehicle. When the vehicle is off or stationary, the MCD 112 can instruct each LCD to enter a sleep mode of operation. The sleep mode of operation can be a relatively low power mode in which the LCD 114 consumes less power than when in an active or relatively high power mode utilized during normal charging or discharging operations of the system 100.

[0343] At step 2420, the MCD 112 sends a synchronization signal to each LCD 114 that is being awakened. The MCD 112 may send the synchronization signal to each LCD via a synchronization path that serves a dual purpose. For example, the synchronization path may be coupled to a synchronization interface of the MCD 112 and may be coupled to both a synchronization interface of each LCD 114 and a wake-up interface (e.g., a wake-up pin) of each LCD 114.

[0344] Each LCD 114 can be configured to monitor the wake-up interface even when the LCD 114 is in the sleep mode of operation. After detecting the synchronization signal at the wake-up interface, the LCD 114 can transition to an active mode of operation, in which the LCD 114 monitors all or most interfaces, operates at a higher frequency, and / or performs other operations that consume more power. The LCD 114 can also wake up a peripheral device in response to detecting the synchronization signal at the wake-up interface.

[0345] At step 2430, the MCD 112 sends the control information and the synchronization information to each LCD 114. As described above, the MCD 112 may send the control information, for example, in the form of control information data elements, over a communication interface (e.g., over a control interface) to the LCD 114. When sending the control information data elements, the MCD 112 sends a synchronization signal over a synchronization path to the LCD 114 to notify the LCD that the control information data elements are being sent, as described above.

[0346] Exemplary Synchronization Techniques

[0347] As described above, various techniques may be used to synchronize the LCD 114 with the transmission of control information packets. Synchronization techniques may also be used to synchronize the PWM controllers 1123 of the array 700 or across multiple arrays 700. Fig. 20These techniques may include the use of data loss events. By accurately synchronizing the PWM controller 1123, the phase shift between the switching signals output by the LCD 114 and the phase shift of its converter output voltage is more accurate and consistent, resulting in excellent system performance.

[0348] Fig.25A is a block diagram of an exemplary embodiment of an LCD 114 configured to implement the synchronization techniques described herein. The LCD 114 may be implemented as an LCD 114 in any of the systems described herein.

[0349] LCD 114 includes PWM controller 1123. As described above, PWM controller 1123 is configured to generate switching signals for switches (e.g., switches S1 to S6) of converter 202 based on a carrier signal for each switch and a modulated reference signal Vrnm. PWM controller 1123 includes switch signal generator 2520 and carrier generator 2530.

[0350] The carrier generator 2530 is configured to generate a carrier signal for the switch of the converter 202 based on the defined phase shift for the converter 202, and provides the carrier signal to the switch signal generator 2520 through the communication path or link 2502. The phase shift is different between different converters, and therefore, the switching signal for the switch of each converter 202 is also different. The carrier generator 2530 includes a PWM counter 2532, which is used to control the phase shift between the carrier signals generated by the carrier generator. When the PWM counter 2532 is reset, the carrier generator 2530 restarts the carrier signal generation process. For example, it is assumed that the carrier generator 2530 generates a phase-shifted carrier signal starting with a first triangle wave with zero phase shift at the beginning of the carrier signal generation process. In this example, when the PWM counter 2532 is reset, the carrier generator 2530 restarts the carrier signal generation process by generating a first triangle wave, and then generates each other phase-shifted triangle wave in sequence according to its phase shift.

[0351] The switch signal generator 2520 is configured to generate a switching signal for each switch of the converter 202 based on the carrier signal received from the carrier generator 2530 and the modulated reference signal Vrnm received from the combiner unit 1121. The switch signal generator 2520 may use a PWM technique, such as but not limited to the PWM technique described herein. Figures 8C to 8FThe described PWM technique generates a switching signal for a module 108 associated with an LCD 114 that performs PWM processing based on a carrier signal and a modulated reference signal Vrnm, and outputs the switching signal to a switch of an associated converter 202 to generate a time-varying output signal from the module 108, wherein the sum of all time-varying output signals from each module 108 of a phase generates an AC output signal of the phase.

[0352] LCD 114 includes a control interface 1742 configured to receive control information, such as control information data elements, from MCD 112 via path or link 115. Similarly, LCD 114 includes a synchronization interface 1743 configured to receive synchronization signals from MCD 112. Each interface 1742 and 1743 may include a driver for the interface, and an isolation unit.

[0353] The LCD 114 also includes a synchronization unit 2510 that is communicatively coupled to the synchronization interface 1743. The synchronization unit 2510 is configured to receive a synchronization signal from the synchronization interface 1743 via a path or link 2505, and detect a synchronization event based on the synchronization signal. The synchronization unit 2510 can be implemented in hardware, software, or a combination thereof within the LCD 114. In some embodiments, the synchronization unit 2510 is implemented as a separate component that is communicatively coupled to the LCD 114 via a path or link.

[0354] The synchronization unit 2510 may be configured to detect a PWM synchronization event and / or a data capture event based on the synchronization signal. The PWM synchronization event indicates a time when the PWM controller 1123 of the array 700 or system 100 is synchronized. The data capture event indicates a time when control information is captured from the path or link 115. For example, the data capture event may indicate that the MCD 112 is sending a control information data element on the path or link 115. Fig.26A An exemplary synchronization unit 2510 is shown in and described below.

[0355] When a data capture event is detected, the synchronization unit 2510 may output a data capture signal to the data capturer 2510 via a communication path or link 2507. The data capturer 2510, which may be implemented in hardware and / or software, may be configured to capture control information from a path or link 2506 between the control interface 1742 and the data capturer 2510, decode the control information to obtain a normalized reference signal Vrn and a modulation index Mi, and store the control information (e.g., in a memory 122). The data capturer 2510 may also provide the normalized reference signal Vrn and the modulation index Mi to the combiner unit 1121 via a communication path or link 2508. As described above, the combiner unit 1121 is configured to modulate or scale the normalized reference signal Vrn using the modulation index Mi to generate a modulated reference signal Vrnm. The control unit 1121 may output the modulated reference signal Vrnm to the PWM controller 1123 via a communication path or link 2501. In other embodiments, the modulated reference signal Vrnm for each module 108 may be generated by the MCD 112 and transmitted directly to each module 108 as allocated.

[0356] When a PWM synchronization event is detected, the synchronization unit 2510 can be configured to output a reset signal to the PWM controller 1123 via the communication path or link 2503. When the PWM controller 1123 detects the reset signal, the PWM controller 1123 can immediately (e.g., without delay) reset the PWM counter 2532. In some embodiments, the synchronization output of the synchronization unit 2510 is directly coupled to a dedicated PWM counter reset input of the PWM controller 1123. For example, if the PWM controller 1123 is implemented as an integrated circuit, the counter reset input can be a pin. In this way, the reset signal is not delayed by the hardware interrupt of the PWM controller 1123.

[0357] Communication paths or links 2501-2503 and 2506-2508 may each be a wired (e.g., electrical, optical) or wireless communication path, similar to communication paths or links 105, 106, 115, 116, and 118, conveying data or information unidirectionally or bidirectionally in parallel or serially.

[0358] Fig.25B1 is a schematic diagram depicting an exemplary embodiment of a communication connection between MCD 112 and LCD 114. In this embodiment, an RS-485 physical layer is used for communication between MCD 112 and LCDs 114-1 to 114-N. MCD 112 includes an RS-485 interface 1564-1, which is configured to send control information to RS-485 interfaces 1742-1 to 1742-N of LCDs 114-1 to 114-N via twisted pair 115. MCD 112 also includes an RS-485 interface 1564-2, which is configured to send synchronization signals to RS-485 interfaces 1743-1 to 1743-N of LCD 114 via twisted pair 1141. Although not shown, MCD 112 and LCD 114 include other components as described herein.

[0359] Each RS-485 interface 1564, 1742, 1743 includes an RS-485 driver and an isolation unit. In an RS-485 physical layer embodiment, the isolation unit may include a capacitor isolator.

[0360] RS-485 and other comparable physical layers are suitable for network topologies, such as various topologies of the system 100 described herein, and enable the use of long-distance paths or links. These physical layers allow high baud rates for transmitting control information to LCD 114, which allows LCD 114 to sample the normalized reference signal Vrn and modulation index Mi at high speed. This improves overall system performance, particularly in terms of harmonics. Some exemplary baud rates include baud rates in the range of 5 megabits / second (Mbit / s) to 10 Mbit / s. For such high baud rates, external synchronization using a synchronization signal enables LCD 114 to determine the start and end of a data packet. This same synchronization signal can also be used to synchronize the PWM controller 1123 of LCD 114. Using the same synchronization signal for these purposes reduces the amount of wires and corresponding insulation, which reduces the size of MCD 112, LCD 114, and the system 100 in which both are implemented, or enables more components in the same size system 100.

[0361] Fig.25C1 is a schematic diagram depicting an exemplary embodiment of a communication connection between an MCD 112 and an LCD 114. In this embodiment, an Ethernet physical layer is used for communication between the MCD 112 and the LCD 114. The MCD 112 includes an Ethernet interface 1513 configured to send control information and synchronization signals to an Ethernet interface 1741 of the LCD 114 over a twisted pair 1141. Although not shown, the MCD 112 and LCD 114 include other components as described herein, and the MCD 112 may be communicatively coupled to multiple LCDs 112 via the same or similar topology.

[0362] Interface 1513 includes an Ethernet driver and transformer isolation unit 2581. Similarly, LCD 114 includes an Ethernet driver 2590 and a transformer isolation unit 2610 (FIG. 26). Isolation units 2581 and 2610 isolate drivers 2580 and 2590 and other components of MCD 112 and LCD 114 from twisted pair 1141, respectively.

[0363] The Ethernet interfaces 1513 and 1741 enable high speed data (e.g., between 100 Mbit / s and 1 Gigabit / second (GB / s)). Using the Ethernet interface enables the MCD 112 to send data (e.g., control information) to the LCD 114 using a high speed carrier signal. The MCD 112 may also include a synchronization signal (e.g., in the form of synchronization pulses) within the carrier signal. This synchronization signal may be implemented using frequency modulation, and the frequency of this synchronization pulse may match the frequency of the PWM frequency of the converter 202 of the LCD. In such an example, a separate synchronization path 1141 would not be needed, resulting in less wires and insulation, and enabling a reduction in the size of the system 100, and enabling more components in a system 100 of the same size.

[0364] Fig.26A 1 is a block diagram of an exemplary embodiment of a synchronization unit 2510. In this embodiment, the synchronization unit 2510 receives a synchronization signal from a synchronization interface 1743 having an isolation unit 2610. The isolation unit 2610 electrically isolates the LCD 114 from the path or link 1141. The type of isolation unit 2610 may be selected based on the physical layer of the path or link through which the synchronization signal is transmitted from the MCD 112 to the LCD 114. For the RS-485 physical layer, the isolation unit 2610 may include a capacitor-based isolator. For the Ethernet physical layer, the isolation unit 2610 may include a transformer-based isolator. Other suitable isolators may be used for these or other types of physical layers.

[0365] In this embodiment, the synchronization unit 2510 includes comparators 2620-1 and 2620-2 and capacitor C1. Comparator 2620-1 is configured to compare the amplitude of the synchronization signal with a first threshold voltage level and output a data capture signal based on the comparison. For example, if the amplitude of the synchronization signal is greater than or equal to the first threshold voltage level, comparator 2620-1 may output a high data capture signal on path or link 2507 to instruct data capturer 2510 to capture control information on communication path or link 2506. The first threshold may be referred to as a data capture threshold.

[0366] The comparator 2620-2 is configured to compare the voltage level across the capacitor C1 with a second threshold voltage level and output a reset signal based on the comparison. For example, if the voltage level across the capacitor is greater than or equal to the second threshold voltage level, the comparator 2620-2 may output a low reset signal on the path or link 2503 to reset the PWM counter 2532. The second threshold may be referred to as a PWM synchronization threshold.

[0367] If the synchronization signal has an alternating amplitude, such as a square wave, capacitor C1 will charge when the amplitude of the synchronization signal is greater than the voltage level of capacitor C1. If the amplitude of the synchronization signal remains at a level that charges capacitor C1 for a sufficient duration, capacitor C1 will charge to a level that meets or exceeds the second threshold, thereby triggering the reset signal. When the synchronization signal is at a low level, capacitor C1 can discharge through the discharge path.

[0368] To initiate a PWM synchronization event, the MCD 112 may adjust the pulse train of the synchronization signal and / or the frequency of the synchronization signal to drive the voltage level of the capacitor above the second threshold. If the physical layer is RS-485, either technique may be used. For example, the MCD 112 may increase the duty cycle of the synchronization signal so that the synchronization signal remains at a high level for a longer duration relative to the cycle length for one or more cycles to drive the voltage level of the capacitor C1 to a higher level than a conventional duty cycle that is not intended to initiate detection of a synchronization event, which may be above the second threshold to cause the comparator 2620-2 to output a low reset signal to reset the PWM counter 2532.

[0369] The MCD 112 may also use a frequency modulated synchronization signal to initiate a PWM synchronization event. During normal operation, the MCD 112 may generate a synchronization signal having a first frequency for initiating a data capture event. To initiate a PWM synchronization event, the MCD 112 may adjust the frequency of the synchronization signal. For example, the MCD 112 may reduce the frequency of the synchronization signal so that the synchronization signal remains at a high level and a low level for a longer duration in each cycle. The high level for a longer duration may cause the capacitor C1 to be charged to a voltage level above the second threshold, thereby causing the comparator 2620-2 to output a high reset signal.

[0370] Fig.26B is a schematic diagram of an exemplary embodiment of a comparator 2620. This embodiment can be used in a synchronization unit 2510 for comparators 2620-1, 2620-2, or as another comparator for initiating another event or action based on a synchronization signal. For simplicity, the comparator 2620 is described in terms of outputting a reset signal on the communication path or link 2503, which is also output by the comparator 2620-2.

[0371] The comparator 2620 is configured to detect a synchronization event based on the synchronization signal and is used in embodiments that include a capacitor-based isolator and / or a transformer-based isolator. Fig.26C Exemplary waveforms of signals associated with capacitor-based isolators are shown in and described below. Fig.26D Exemplary waveforms of signals associated with transformer-based isolators are shown in FIG. 1 and described below.

[0372] As described above, the comparator 2620 may be configured to compare the voltage level of the capacitor C1 with a threshold voltage level. Fig.26B The C1 in the sync unit 2510 may be the same as the C1 of the sync unit 2510. The comparator 2620 may include a timer circuit 1743 for comparing the voltage level of the capacitor C1 with a threshold value. The timer circuit 1743 may be implemented as a 555 timer (which is an integrated circuit configured to perform various timer and pulse generation operations), another timer circuit configured to perform a comparison operation, or another type of circuit configured to perform a comparison operation.

[0373] In this embodiment, the timer circuit 1763 includes a Vcc input for receiving a positive supply voltage, a discharge output (DIS), a threshold input (THRS), a control voltage input (CV), a ground input (GND) coupled to ground, a trigger input (TRIG), an output (OUT) coupled to the path or link 2503, and a reset input (RST).

[0374] The comparator 2620 includes a transistor Q1, which can be implemented as an IGBT, a MOSFET, a GaN transistor, or other types of transistors. The gate of the transistor Q1 is coupled to the synchronization signal, and the emitter or source of the transistor Q1 is coupled to the power supply voltage via a resistor R1 and coupled to the discharge output. When the voltage level of the synchronization signal is at a high level, the capacitor C1 is charged by the power supply voltage via the resistor R1.

[0375] When the voltage level of capacitor C1 reaches the threshold voltage level, the internal logic of timer circuit 1763 pulls down output pin OUT, which generates a short low voltage (e.g., at or about 0 VDC or GND potential) pulse on path or link 2503, which initiates a synchronization event. Otherwise, output pin OUT has a high voltage output, e.g., at or about 5 VDC or a potential of a power supply voltage coupled to Vcc.

[0376] Specifically, the internal logic of the timer circuit 1743 compares the voltage level at the threshold input pin THRS with the control voltage input at the pin CV. When the voltage level at the threshold input pin THRS is greater than the control voltage input at the pin CV, the internal logic of the timer circuit 1763 pulls down the output pin OUT. When the output is low, the internal logic of the timer circuit 1743 causes the discharge output to discharge the capacitor C1 so that the output returns to a high voltage level on the path or link 2503.

[0377] Fig.26C 26 is a plot 2630 depicting waveforms 2631 through 2633 of signals associated with the synchronization unit 2510. These waveforms 2631 through 2633 may represent waveforms of the synchronization unit 2510 having or coupled to the capacitor-based isolation unit 2610. The plot 2630 depicts a voltage waveform 2631 of the voltage of the capacitor C1, a voltage waveform 2632 of an output signal (e.g., a data capture signal on path or link 2507 or a reset signal on path 2503), and a voltage waveform 2633 of a synchronization signal.

[0378] For most pulses, the voltage waveform 2633 of the synchronization signal generally has a normal pulse width 2633-1. This causes the capacitor C1 to charge to a first level 2631-1, which may be less than a threshold to initiate a synchronization event, so that the output waveform remains at a high level 2632-1. To initiate a synchronization event, the synchronization signal may be adjusted to have a longer pulse width 2633-1 at a high level. This causes the capacitor C1 to charge to a higher level 2632-2, which in turn causes the output (e.g., the output of the timer circuit 1743) to drop to a low level 2632-2.

[0379] Fig.26D2640 is a plot 2641 through 2643 depicting waveforms of signals associated with the synchronization unit 2510. These waveforms 2641 through 2643 may represent waveforms of the synchronization unit 2510 having or coupled to the transformer-based isolation unit 2610. The main difference between the waveforms 2631 through 2633 and the waveforms 2641 through 2643 is the shape of the waveforms 2631 and 2641.

[0380] Plot 2640 depicts a voltage waveform 2641 of the voltage of capacitor C1 , a voltage waveform 2642 of an output signal (eg, a data capture signal on path or link 2507 or a reset signal on path 2503 ), and a voltage waveform 2643 of a synchronization signal.

[0381] For most pulses, the voltage waveform 2643 of the synchronization signal generally has a normal pulse width 2643-1. This causes the capacitor C1 to charge to a first level 2641-1, which may be less than a threshold to initiate a synchronization event, so that the output waveform remains at a high level 2642-1. To initiate a synchronization event, the synchronization signal may be adjusted to have a longer pulse width 2643-1 at a high level. This causes the capacitor C1 to charge to a higher level 2642-2, which in turn causes the output (e.g., the output of the timer circuit 1743) to drop to a low level 2642-2. Fig. 27 27 is a plot 2700 depicting frequency modulated synchronization signals 2710 and 2720 and a voltage level 2730 of capacitor C1 of synchronization unit 2510. MCD 112 may send frequency modulated synchronization signal 2710 to LCD 114, and LCD 114 may receive frequency modulated synchronization signal 2720.

[0382] During a first time period (Cycle 1), the frequency of the frequency modulated synchronization signal 2710 remains constant. Therefore, the voltage level 2730 of capacitor C1 charges to a first threshold level 2740 (e.g., a data capture threshold) at each cycle of the frequency modulated synchronization signal 2710. Since the frequency is constant, capacitor C1 charges to approximately the same value at each cycle.

[0383] During a second time period (cycle 2), the MCD 112 reduces the frequency of the frequency modulated synchronization signal 2710 within one cycle of the frequency modulated synchronization signal 2710. Since the synchronization signal 2710 remains at a high level for a longer time than previously in cycle 1 (as indicated by reference numeral 2711), the voltage level of the capacitor C1 charges above a second threshold 2750 (e.g., a PWM synchronization threshold) at reference numeral 2731, which is higher than the first threshold 2740. For example, the first threshold 2740 may be used to initiate a data capture event, and the second threshold 2750 may be used to initiate a PWM synchronization event. Thus, the reduced frequency of the frequency modulated signal during cycle 2 may charge the capacitor C1 to a voltage level that initiates a PWM synchronization event. Whenever synchronization of the PWM controller 1123 is guaranteed, the MCD 112 may reduce the frequency of the frequency modulated signal to the frequency shown in cycle 2, and then return the frequency to the frequency of cycle 1 or cycle 3 to prevent detection of another PWM synchronization event until the MCD 112 initiates another PWM synchronization event.

[0384] Fig.28 28 is a plot 2800 depicting a frequency modulated synchronization signal 2810 and a reset signal 2820 generated based on the frequency modulated synchronization signal 2810. The MCD 112 may generate the frequency modulated signal 2810 and send it to the LCD 114. The synchronization unit 2510 may detect a synchronization event based on the frequency of the frequency modulated synchronization signal 2810. Fig.28 The frequency modulated synchronization signal and periods 1 to 3 can be used with Fig. 27 The frequency modulated signal 2710 is the same or similar to periods 1 to 3.

[0385] During a first time period (Cycle 1), the frequency of the frequency modulated synchronization signal 2810 remains constant at a sufficiently high frequency that does not allow capacitor C1 of synchronization unit 2510 to reach the threshold for detecting a PWM synchronization event. During a second time period (Cycle 2), MCD 112 decreases the frequency of the frequency modulated synchronization signal 2810, thereby causing the voltage level of C1 to reach each threshold, thereby generating a low reset signal 2820 during Cycle 2. When MCD 112 increases the frequency of the frequency modulated synchronization signal 2810 to the previous level of Cycle 1, reset signal 2820 remains high during a third cycle (Cycle 3).

[0386] Fig.29 is a flow chart depicting an exemplary embodiment of a method 2900 for synchronizing data capture events and PWM events. The method 2900 may be performed by an energy system including an MCD 112 and one or more arrays 700 of cascade modules 108. For example, the method 2900 may be performed by any of the systems 100 described in this document.

[0387] At step 2910, the MCD 112 generates and sends a regular synchronization signal to the LCDs 114 of the modules 108 in one or more arrays 700 of the system 100. In some embodiments, the MCD 112 sends the regular synchronization signal to each LCD 114 in the array 700. For multi-phase embodiments, the MCD 112 may send the same or different synchronization signals to the LCDs 114 of the array 700 for each phase.

[0388] The synchronization signal may be a modulated voltage waveform with alternating amplitude, such as a square wave voltage signal. The regular synchronization signal may have a constant (or at least close to constant within a specified tolerance) amplitude and frequency. The MCD 112 may generate a regular synchronization signal and provide it to the LCD 114 to initiate a data capture event.

[0389] The MCD 112 may also send control information to the LCD 114 based on the regular synchronization signal. For example, the MCD 112 may send the control information over the communication path or link 115 during the time that the regular synchronization signal is at a particular level (e.g., at or above a particular voltage level) or in a particular state (e.g., a high state). In this manner, the MCD 112 may inform the LCD 114 which control information is being sent to the LCD 114 using the synchronization signal.

[0390] At step 2920, LCD 114 detects a data capture event based on the synchronization signal. As described above, LCD 114 can be configured to compare the amplitude of the synchronization signal to a data capture threshold. Whenever the amplitude of the synchronization signal meets the data capture threshold, for example, by meeting or exceeding the data capture threshold, LCD 114 can detect a data capture event.

[0391] At step 2921, LCD 114 captures control information on communication path or link 115. LCD 114 may capture control information packets on the communication path or link in response to detecting a data capture event. LCD 114 may capture control information as described elsewhere herein.

[0392] At step 2922, LCD 114 controls converter 202 based on the captured control information. As described above, LCD 114 may be configured to modulate or scale the normalized reference signal Vrn of the control information using the modulation index Mi of the control information specified for LCD 114 to generate a modulated reference signal Vrnm. LCD 114 may use the modulated reference signal Vrnm to control the switches of converter 202. As described above, LCD 114 may continue to operate the switches of converter 202 using the control information specified for LCD 114 until updated control information specified for LCD 114 is captured from path or link 115.

[0393] At step 2911 , the MCD 112 determines whether to initiate a synchronization event. For example, the MCD 112 may determine to initiate a PWM synchronization event. The PWM synchronization event synchronizes the PWM controllers of each LCD 114 in the array 700 or multiple arrays 700 of the system 100 .

[0394] The MCD 112 may periodically initiate a PWM synchronization event based on a specified time period. For example, the MCD 112 may restart a timer after initiating each PWM synchronization event and initiate a new PWM synchronization event when the timer expires. The MCD 112 may also initiate a PWM synchronization event to change the frequency of the PWM, synchronize the data acquisition process between the MCD 112 and the LCD 114, and / or wake up a dormant LCD 114. If the MCD 112 determines not to initiate a PWM synchronization event, the method 2900 returns to step 2910, where the MCD 112 generates a regular synchronization signal and sends it to the LCD 114.

[0395] At step 2912, the MCD 112 adjusts the synchronization signal for a period of time in response to determining to initiate a PWM synchronization event and / or other type of synchronization event or action. For example, the MCD 112 may adjust the synchronization signal for a specified duration (e.g., in seconds, milliseconds, or microseconds) or for a specified number of cycles of the synchronization signal (e.g., one, two, five, or another suitable number of cycles). The MCD 112 may adjust the synchronization signal to initiate a PWM synchronization event to synchronize a PWM counter of the LCD 114, wake up the LCD 114, synchronize a data capture event, and / or initiate another event or action.

[0396] In some embodiments, the synchronization signal is a frequency modulated synchronization signal. In this example, the MCD 112 is configured to adjust the frequency of the synchronization signal. For example, the MCD 112 can reduce the frequency of the synchronization signal to increase the voltage across the capacitor C1 (FIG. 26) to initiate each LCD 114 to detect a PWM synchronization event.

[0397] In some embodiments, the MCD 112 is configured to adjust the duty cycle of the synchronization signal. For example, the MCD 112 can increase the duty cycle of the synchronization signal so that the synchronization signal remains at a high level for a longer duration in each cycle to drive the voltage level of the capacitor C1 (FIG. 26) to a higher level than the regular duty cycle of the regular synchronization signal.

[0398] In some embodiments, MCD 112 may be configured to adjust the amplitude of the pulses of the synchronization signal. For example, MCD 112 may increase the amplitude of the pulses of the synchronization signal to drive the voltage level of capacitor C1 (FIG. 26) to a higher level than the regular amplitude of the regular synchronization signal.

[0399] After the time period expires, the MCD 112 may adjust the synchronization signal back to a regular synchronization signal.

[0400] At step 2923, LCD 114 detects a PWM synchronization event. As described above, LCD 114 can be configured to compare the magnitude of the voltage of capacitor C1 (FIG. 26) to a PWM synchronization threshold. Whenever the magnitude of capacitor C1 meets the PWM synchronization threshold, for example, by meeting or exceeding the PWM synchronization threshold, LCD 114 can detect a PWM synchronization event.

[0401] At step 2924, LCD 114 resets PWM counter 2532 of PWM controller 1123. For example, LCD 114 may send a reset signal to PWM controller 1123, such as to a reset pin of a PWM controller integrated circuit. This is an example of a synchronization action that may be performed by LCD 114 in response to detecting a synchronization event.

[0402] In another example, LCD 114 detects a data capture event whenever the magnitude of capacitor C1 satisfies the data capture threshold, such as by meeting or exceeding the data capture threshold. In response, LCD 114 may begin monitoring control information from MCD 112, such as at control interface 1742.

[0403] Although the exemplary method 2900 includes detecting a data capture event and controlling the converter 202 based on the control information captured in response to detecting the data capture event, these steps may be omitted in some embodiments. For example, in some embodiments, the MCD 112 may initiate a PWM synchronization event by adjusting the synchronization signal in steps 2911 to 2913, and the LCD 114 may detect the PWM synchronization event and reset the PWM counter 2532 without using the synchronization steps 2920 to 2922 to synchronize the capture of the control information.

[0404] In some embodiments, data missing events are used to synchronize the capture of control information data elements and / or synchronize the PWM controllers 1123 of the LCDs 114 in one or more arrays 700. For example, Fig. 20 The method 2000 may be modified to include an additional step (eg, before, after, or in parallel with step 2030) of resetting the PWM counter 2532 in response to each determination in step 2026 that a control information data element has been received.

[0405] Fig.30 2900 is a flow chart depicting an exemplary embodiment of a method 3000 for synchronizing data capture events and PWM events. The method 3000 is another example in which data missing events can be used to synchronize the capture of control information data elements and / or synchronize the PWM controllers 1123 of the LCDs 114 in one or more arrays 700. The method 2900 can be performed by an energy system that includes one or more arrays 700 of MCDs 112 and cascaded modules 108. For example, the method 2900 can be performed by any of the systems 100 described in this document.

[0406] At step 3010, LCD 114 detects a first data unit on a communication interface connected to the communication path after at least a threshold duration since receiving a previous control information data element. Step 3010 may be associated with Fig. 20 Step 2010 of method 2000 is implemented in the same or similar manner.

[0407] At step 3020, LCD 114 determines whether a new control information data element containing the detected data unit has been received. LCD 114 may be configured to determine that a new control information data element has been received when there is no data on the path or link 115 for a specified duration after the last received data unit. LCD 114 may use steps 3021 to 3024 to determine whether a data loss event has occurred, and therefore determine whether a new control information data element has been received.

[0408] At step 3021, LCD 114 starts a timer for a specified time period. The time period may be based on an expected duration between receipt of consecutive data units (e.g., data segments) of a control information data element (e.g., in the form of a data frame). In some embodiments, the time period may be longer than this expected duration to account for delays in transmission. For example, the time period may be based on a duration for receiving one data unit, two data units, three data units, or another appropriate number of data units. In another example, the time period may be a multiple of the expected duration, for example, twice the expected duration, three times the expected duration, and / or another appropriate multiple.

[0409] At step 3022, LCD 114 determines whether any additional data units are received before the timer expires. If received, method 3000 returns to step 3021 of resetting the timer. If not received, LCD 114 determines at step 3024 that a data missing event has occurred. In response to determining that a data missing event has occurred, LCD 114 may determine that a control information data element has been received.

[0410] At step 3030, LCD 114 resets the PWM counter 2532 of PWM controller 1132. For example, LCD 1134 may send a reset signal to PWM controller 1123, such as to a reset pin of a PWM controller integrated circuit.

[0411] At step 3040, LCD 114 processes the received control information data element. Step 3040 may be associated with Fig. 20 Step 2010 of method 2030 is implemented in the same or similar manner.

[0412] The synchronization techniques described above utilizing synchronization signals reduce the amount of jitter that would otherwise be present in the synchronization signals received by the LCD 114 and improve the accuracy of synchronization of the PWM controllers 1123 of the multiple modules 108 in one or more arrays 700 of the system 100. Jitter refers to the variation between a signal and an ideal signal (e.g., an output waveform). Imprecise synchronization between the LCDs 114 may result in jitter on the switching signals output by the LCDs 114. Jitter may be caused by uncontrolled execution times of software and low-level interrupts of the processor and / or controller implementing the control logic. Jitter may include increases and / or decreases in signal levels, for example, in a short amount of time during which a signal rises and / or falls.

[0413] For example, resetting the PWM counter 2532 of one LCD 114 in array 700 before resetting the PWM counter 2532 of another LCD 114 in array 700 may result in an inaccurate phase shift in its carrier signal, thereby resulting in inaccurate timing of the switching signals of converter 202 and a distorted output voltage of system 100. Using the synchronization techniques described above, this jitter is reduced, resulting in more accurate synchronization and corresponding switching signals, thereby producing a higher quality output voltage.

[0414] Fig.31 31 is a plot 3100 depicting jitter present on switching signals output by LCD 114. Plot 3100 illustrates jitter present on rising edges of switching signals 3110 through 3140 generated by LCDs 114 of four different modules 108 of array 700 based on PWM synchronization events. For switching signal 3210, jitter is present during jitter time period 3150. Similar jitter is present on rising edges of switching signals 3120, 3130, and 3140 during similar time periods.

[0415] Fig.32 is a plot 3200 depicting reduced jitter present on a switching signal output by LCD 114. This plot 3200 may have the same time scale as plot 3100 to demonstrate reduced jitter resulting from use of system 100, synchronization unit 2510 thereof, and / or synchronization techniques described herein.

[0416] Plot 3200 depicts a voltage waveform 3210 of a synchronization signal input to the synchronization unit 2610, a reset signal 3220 output by the synchronization unit 2610, a voltage waveform 3230 of a switching signal output by the first LCD 114 receiving the reset signal output by the synchronization unit 2610, and a switching signal output by the second LCD 114 receiving the reset signal output by the synchronization unit 2610.

[0417] Here, for most pulses, the voltage waveform 3210 of the synchronization signal generally has a normal pulse width 3210-1. In order to initiate a synchronization event, the synchronization signal can be adjusted to have a longer pulse width 3210-2 at a high level. This causes the output voltage 3220 to drop from a high level 3220-1 to a low level 3220-2 within a short pulse, as described above.

[0418] In this example, each LCD 114 uses the rising edge of the synchronization signal to reset the PWM counter 2532. As described above, when the PWM counter 2532 is reset, the carrier generator 2530 restarts the carrier signal generation process. Fig.32As shown in FIG. 1 , the magnitude and duration of the jitter 3231 and 3241 shown on the rising edges of waveforms 3230 and 3241, respectively, are greater than Fig.31 The magnitude and duration are much smaller.

[0419] In the following, various aspects of the subject matter of the present invention are described to review and / or supplement the embodiments described so far, with emphasis on the interrelationship and interchangeability of the following embodiments. In other words, unless otherwise explicitly stated or taught, emphasis is placed on the fact that each feature of the embodiment can be combined with each other feature.

[0420] In many embodiments, an energy system includes an array of cascaded modules configured to output a voltage waveform and / or a current waveform to a load. In these embodiments, each module includes an energy source, a switching circuit system, and a local control device, and each module has an identifier. The energy system may include a master control device that is communicatively coupled to each local control device via a communication path and is configured to send a control information data element to the local control device via the communication path. Each control information data element may include a normalized reference signal for each module in the cascaded module array, a single identifier selected from a group of identifiers including the identifier for each module in the cascaded module array, and a modulation index for the module having the single identifier. The local control device of each module may be configured to scale the normalized reference signal of the most recently received control information data element by the modulation index of the most recently received control information data element with the identifier of the module to produce a scaled reference signal, and use the scaled reference signal to control the switch circuit system of the module.

[0421] In many embodiments, the master control device periodically sends the control information data elements to the local control devices according to a sequence that defines the order of modules in which updated modulation indices are sent to the modules using the control information data elements.

[0422] In many embodiments, the local control device of each module is configured to determine whether the selected identifier of each control information data element matches the identifier of the module. When the selected identifier of the control information data element matches the identifier of the module, the local control device of the module may scale the normalized reference signal of the control information data element using the modulation index of the control information data element. When the selected identifier of the control information data element does not match the identifier of the module, the local control device of the module may scale the normalized reference signal of the control information data element using the modulation index of the most recently received control information data element having the identifier of the module.

[0423] In many embodiments, the master control device includes a controller configured to generate respective modulation indices for the modules.

[0424] In many embodiments, the modulation index for at least one module in the cascaded array of modules is different from the modulation index for at least one other module in the cascaded array of modules. The energy system may include a bidirectional data path that communicatively couples each local control device to the master control device. Each local control device may be configured to send status information for the module including the local control device to the master control device via the bidirectional data path. The controller may generate the modulation index for each module using the status information received from each local control device. The status information for each module may include one or more of a charge state of the energy source of the module, a health state of the energy source of the module, or a temperature of the energy source of the module.

[0425] In many embodiments, the communication path comprises a serial communication path.

[0426] In many embodiments, a method of controlling a voltage or current supplied to a load includes sending a control information data element by a master control device through a communication path to a local control device of a cascaded module array, the cascaded module array being configured to output a voltage waveform and / or a current waveform to a load. Each module includes an energy source, a switching circuit system, a local control device, and an identifier. Each control information data element includes a normalized reference signal for each module in the cascaded module array, a single identifier selected from a group of identifiers including the identifier for each module in the cascaded module array, and a modulation index for the module having the single identifier. The method may include scaling the normalized reference signal of the most recently received control information data element by each local control device by the modulation index of the most recently received control information data element having the identifier of the module to produce a scaled reference signal, and using the scaled reference signal to control the switching circuit system of the module.

[0427] In many embodiments, sending the control information data elements to the local control device of the cascaded module array includes the master control device periodically sending the control information data elements to the local control device according to a sequence, wherein the sequence uses the control information data elements to define the module order in which updated modulation indices are sent to the modules.

[0428] In many embodiments, the method includes, for each module in the array of cascaded modules, determining, by the local control device of the module, whether the selected identifier of each control information data element matches the identifier of the module. The method may include, when the selected identifier of a control information data element matches the identifier of the module, scaling, by the local control device of the module, the normalized reference signal of the control information data element using the modulation index of the control information data element. The method may include, when the selected identifier of the control information data element does not match the identifier of the module, scaling, by the local control device of the module, the normalized reference signal of the control information data element using the modulation index of the most recently received control information data element having the identifier of the module.

[0429] In many embodiments, the method includes generating, by a controller of the master control device, respective modulation indices for the modules.

[0430] In many embodiments, the modulation index for at least one module in the cascaded array of modules is different from the modulation index for at least one other module in the cascaded array of modules. The method may include sending, by each local control device, status information for the modules including the local control device via a bidirectional data interface that communicatively couples each local control device to the master control device. In many embodiments, the controller generates the modulation index for each module using the status information received from each local control device. In many embodiments, the status information for each module includes one or more of a charge state of the energy source of the module, a health state of the energy source of the module, or a temperature of the energy source of the module.

[0431] In many embodiments, the communication path comprises a serial communication path.

[0432] In many embodiments, an energy system includes an array of cascaded modules configured to output a voltage waveform and / or a current waveform to a load. Each module includes an energy source, a switching circuit system, and a local control device, the local control device controlling the switching circuit system based at least in part on a received normalized reference signal. The energy system may include a master control device that is communicatively coupled to each local control device via a communication path and configured to send a control information data element to the local control device via the communication path. Each control information data element may include a normalized reference signal. Each local control device may be configured to detect a first data unit on the communication path after at least a threshold duration since a previous control information data element was received, determine that the new control information data element has been received based on the duration that has elapsed since the first data unit was received and whether additional data units are received after a data reception time period of a new control information data element containing the first data unit, and process the new control information data element.

[0433] In many embodiments, determining that the new control information data element has been received includes: initiating a time for the data reception time period in response to detecting the first data unit; receiving additional data units during the data element reception time period; determining whether any additional data elements are received during a post-reception time period; and determining that the new control information data element has been received based on the elapse of the data element reception time period and a determination that the additional data units were not received during the post-reception time period.

[0434] In many embodiments, the data reception time period is based on the data size of each control information data element and the data rate for the communication path. The data reception time period may be longer than the expected time period for receiving control information data elements. The data reception time period may include a duration for receiving data having a data size that is one or two bytes larger than the data size of each control information data element. Processing the new control information data element may include operating the switch circuit system using the normalized reference signal and a modulation index for the module including the local control device. The local control device is configured to operate the switch circuit system using a previously stored normalized reference signal of a previously received control information data element whenever a received control information data element is damaged or not fully received.

[0435] In many embodiments, a method of controlling a voltage or current supplied to a load includes sending, by a master control device, a control information data element to a local control device of a cascaded module array via a communication path, the cascaded module array being configured to output a voltage waveform and / or a current waveform to the load. Each module includes an energy source, a switch circuit system, and a local control device, the local control device controlling the switch circuit system based at least in part on a received normalized reference signal. The method may include detecting, by the local control device, a first data unit on the communication path after at least a threshold duration since a previous control information data element was received. The method may include determining, by the local control device, that a new control information data element has been received based on a duration that has elapsed since the first data unit was received and whether additional data units are received after a data reception time period of a new control information data element including the first data unit, and processing the new control information data element.

[0436] In many embodiments, determining that the new control information data element has been received includes: initiating a time for the data reception time period in response to detecting the first data unit; receiving additional data units during the data element reception time period; determining whether any additional data elements are received during a post-reception time period; and determining that the new control information data element has been received based on the elapse of the data element reception time period and a determination that the additional data units were not received during the post-reception time period.

[0437] In many embodiments, the data reception time period is based on the data size of each control information data element and the data rate for the communication path. The data reception time period may be longer than the expected time period for receiving control information data elements. The data reception time period may include a duration for receiving data having a data size that is one or two bytes larger than the data size of each control information data element. Processing the new control information data element may include operating the switch circuit system using the normalized reference signal and the modulation index for the module including the local control device. The local control device may be configured to operate the switch circuit system using the previously stored normalized reference signal of the previously received control information data element whenever the received control information data element is damaged or not fully received.

[0438] In many embodiments, an energy system includes an array of cascaded modules configured to output a voltage waveform and / or a current waveform to a load. Each module may include an energy source, a switch circuit system, and a local control device, the local control device controlling the switch circuit system based at least in part on a received normalized reference signal. The energy system may include a master control device, the master control device being communicatively coupled to each local control device via a control path and a synchronization path and sending a control information data element to the local control device via the control path. Each control information data element may include a normalized reference signal for each module in the cascaded modules and a modulation index for scaling the reference signal. The master control device may send a synchronization signal to the local control device via the synchronization path. The synchronization signal may indicate when a control information data element is sent to the local control device.

[0439] In many embodiments, the local control device of each module is configured to detect the synchronization signal and to capture the control information data element in response to detecting the synchronization signal.

[0440] In a number of embodiments, the master control means is configured to remove the synchronization signal after completing transmission of the control information data element.The local control means of each module may be configured to stop capturing the control information data element in response to detecting that the synchronization signal has been removed.

[0441] In many embodiments, sending the synchronization signal includes increasing a voltage level on a synchronization signal bus coupled to the master control device and the local control device of each module in the cascaded module array. Removing the synchronization signal may include decreasing a voltage level on the synchronization signal bus.

[0442] In many embodiments, each local control device is configured to wake up the module containing the local control device from sleep mode in response to detecting the synchronization signal.The master control device may be configured to send the synchronization signal in response to determining to wake up the module in the cascaded module array.

[0443] In many embodiments, a method of controlling a voltage or current supplied to a load includes sending, by a master control device, a control information data element to a local control device of a cascaded module array via a control path, the cascaded module array being configured to output a voltage waveform and / or a current waveform to the load. Each module may include an energy source, a switch circuit system, and a local control device, the local control device controlling the switch circuit system based at least in part on a received normalized reference signal. The master control device may be communicatively coupled to each local control device via a control path and via a synchronization path. Each control information data element may include a normalized reference signal for each module in the cascaded module and a modulation index for scaling the reference signal. The method may include sending a synchronization signal to the local control device via the synchronization path. The synchronization signal may indicate when a control information data element is sent to the local control device.

[0444] In many embodiments, the method includes detecting, by the local control device of each module, the synchronization signal, and capturing, by the local control device of each module in response to detecting the synchronization signal, the control information data element.

[0445] In a number of embodiments, the method comprises removing, by the master control device, the synchronization signal after completing transmission of the control information data element.The local control device of each module may be configured to stop capturing the control information data element in response to detecting that the synchronization signal has been removed.

[0446] In many embodiments, sending the synchronization signal includes increasing a voltage level on a synchronization signal bus coupled to the master control device and the local control device of each module in the cascaded module array. Removing the synchronization signal may include decreasing a voltage level on the synchronization signal bus.

[0447] In many embodiments, each local control device is configured to wake up the module including the local control device from a sleep mode in response to detecting the synchronization signal.Sending the synchronization signal to the local control device through the synchronization path may include sending the synchronization signal in response to determining to wake up the module in the cascaded module array.

[0448] In many embodiments, an energy system configured to generate split-phase AC power includes a first module array and a second module array. Each module in the first and second arrays may include a converter coupled to an energy source. The first array may be configured to generate a first AC signal between a first output and a second output of the first array, the first AC signal having a first phase angle. The second array may be configured to generate a second AC signal having a second phase angle between a first output and a second output of the second array, the second phase angle being 180 degrees different from the first phase angle. The first output of the first array may be connected to a first system output terminal (L1). The first output of the second array may be connected to a second system output terminal (L2). The second outputs of the first array and the second array may be connected to a third system output terminal (N).

[0449] In many embodiments, each module includes a local control device configured to control the switching circuitry of the converter of the module based on the normalized reference signal and the modulation index. The energy system may include a master control device configured to send a first control information data element to each module in the first array and a second control information data element to each module in the second array. Each first control information data element may include a first normalized reference signal for each module in the array of the first array and a single first identifier selected from a set of first identifiers for the modules in the first array. The set of first identifiers may include a first identifier for each module in the first array. Each first control information data element may include a first modulation index for the module in the first array with the single first identifier. Each second control information data element may include a second normalized reference signal for each module in the array of the second array and a single second identifier selected from a set of second identifiers for the modules in the second array. The set of second identifiers may include a second identifier for each module in the second array. Each second control information data element may include a second modulation index for the module in the second array with the single second identifier.

[0450] In many embodiments, the local control device of each module in the first array is configured to scale the first normalized reference signal of the most recently received first control information data element by the first modulation index of the most recently received control information data element having the identifier of the module in the first array to produce a scaled reference signal, and use the scaled reference signal to control the switching circuit system of the converter of the module in the first array.

[0451] In many embodiments, the master control device periodically sends the first control information data element to each module in the first array according to a sequence that uses the first control information data element to define the order of modules in which updated modulation indices are sent to the modules.

[0452] In many embodiments, a method for waking up a local control device includes determining, by a master control device that is communicatively coupled to the local control devices of each module in a cascaded module array via a synchronization path, to wake up each local control device from a sleep operation mode, and sending, by the master control device, a synchronization signal to a wake-up interface of each local control device via the synchronization path in response to determining to wake up each local control device from the sleep operation mode.

[0453] In many embodiments, the method includes sending a synchronization signal by the master control device over the synchronization path to each local control device whenever the master control device sends a control information data element to each local control device. The synchronization signal indicates to each local control device that the master control device is sending the control information data element. The method may include sending the control information data element by the master control device to each local control device over a control path that communicatively couples the master control device to each local control device. Each control information data element may include a normalized reference signal for each module in the array, a single identifier selected from a set of identifiers for the modules in the array. The set of identifiers may include an identifier for each module in the array. Each control information data element may include a first modulation index for the module in the first array having the single identifier. A first purpose of the synchronization path may be to indicate to each local control device when a control information data element is sent to each local control device, and a second purpose may be to wake each local control device from the sleep mode of operation.

[0454] In many embodiments, an energy control system includes modules configured to be connected together to output a voltage waveform and / or a current waveform to a load. Each module may include an energy source, a switching circuit system, and a local control device. The energy control system may include a master control device configured to send control information to each local control device via a communication path. The control information may include reference signal information, modulated index information, and an identifier that associates the modulation index information with one of the modules.

[0455] In many embodiments, the modules are arranged in a cascaded array.

[0456] In many embodiments, the control information may include control information data elements. Each control information data element may include the reference signal information for all modules in the set of modules, the modulation index information for the one module, and the identifier. The local control device of each module may be configured to scale the reference signal information of the most recently received control information data element by the modulation index information of the most recently received control information data element with the identifier of the module to produce a scaled reference signal. The local control device of each module may be configured to control the switch circuit system of the module using the scaled reference signal.

[0457] In many embodiments, the master control device periodically sends the control information to the local control devices according to a sequence that defines the order of modules in which updated modulation index information is sent to the modules.

[0458] In many embodiments, the local control of each module is configured to determine whether the identifier matches an identifier of the module. When the identifier matches the identifier of the module, the local control of the module may scale the reference signal information using the modulation index information. When the identifier does not match the identifier of the module, the local control of the module may scale the reference signal information using previously stored modulation information for the module.

[0459] In many embodiments, the master control device includes a controller configured to generate corresponding modulation index information for the modules.

[0460] In many embodiments, a method of controlling a voltage or current supplied to a load includes sending control information by a master control device through a communication path to each local control device of a plurality of modules, the plurality of modules being configured to be connected together to output a voltage waveform and / or a current waveform to the load. Each module of the plurality of modules may include an energy source, a switching circuit system, and a local control device. The control information may include reference signal information, modulated index information, and an identifier associating the modulation index information with one of the plurality of modules.

[0461] In many embodiments, the plurality of modules are arranged in a cascade array.

[0462] In many embodiments, the control information includes control information data elements. Each control information data element may include the reference signal information for all modules in the set of modules, modulation index information for the one module, and the identifier. The method may include scaling, by each local control device, the reference signal information of a most recently received control information data element with the modulation index information of the most recently received control information data element with the identifier of the module to produce a scaled reference signal, and controlling, by each local control device, the switch circuitry of the module using the scaled reference signal.

[0463] In many embodiments, the master control device periodically sends the control information to the local control devices according to a sequence that defines the order of modules in which updated modulation index information is sent to the modules.

[0464] In many embodiments, the method includes determining, by each local control device, whether the identifier matches an identifier of the module. The method may include scaling, by the local control device, the reference signal information using the modulation index information when the identifier matches the identifier of the module. The method may include scaling, by the local control device, the reference signal information using previously stored modulation information for the module when the identifier does not match the identifier of the module.

[0465] In many embodiments, the master control device includes a controller configured to generate corresponding modulation index information for the modules.

[0466] In many embodiments, a method of synchronizing modules of an energy system includes generating a synchronization signal by a master control device that is communicatively coupled to a local control device of each module. The master control device sends the synchronization signal to the local control device of each local control device. The master control device adjusts the synchronization signal to initiate a synchronization event. The adjustment includes adjusting at least one of a duty cycle or a frequency of the synchronization signal. Each local control device detects the synchronization event based on the adjusted synchronization signal. Each local control device performs a synchronization action in response to detecting the synchronization event.

[0467] In many embodiments, performing the synchronization action includes resetting a pulse width modulation (PWM) controller of the module. The PWM controller is configured to generate a PWM switching signal for a converter of the module.

[0468] In many embodiments, resetting the PWM controller includes resetting a PWM counter of the PWM controller.

[0469] In many embodiments, the PWM controller includes a carrier generator that generates a carrier signal for generating the PWM switching signal based on the PWM counter.

[0470] In many embodiments, generating the synchronization signal includes generating a regular synchronization signal having a regular frequency and amplitude.

[0471] In many embodiments, the method includes detecting a data capture event based on the regular synchronization signal.

[0472] In many embodiments, the method includes capturing data from a path or link communicatively coupling the master control device to the local control device in response to detecting the data capture event.

[0473] In many embodiments, detecting the synchronization event includes applying the synchronization signal to a capacitor, comparing a voltage of the capacitor to a threshold voltage level, and detecting the synchronization event when the voltage of the capacitor is greater than or equal to the threshold voltage level.

[0474] In many embodiments, adjusting the synchronization signal includes reducing the frequency of the synchronization signal.

[0475] In many embodiments, a method of synchronizing modules of an energy system includes detecting, by a local control device, a data loss event on a communication path that communicatively couples a master control device to the local control device. In response to detecting the data loss event, performing a synchronization action.

[0476] In many embodiments, performing the synchronization action includes resetting a pulse width modulation (PWM) controller of the module. The PWM controller may be configured to generate a PWM switching signal for a converter of the module.

[0477] In many embodiments, resetting the PWM controller includes resetting a PWM counter of the PWM controller.

[0478] In many embodiments, the PWM controller includes a carrier generator that generates a carrier signal for generating the PWM switching signal based on the PWM counter.

[0479] In many embodiments, detecting the data missing event includes detecting a first data unit on the communication path after at least a threshold duration since receiving a previous data element, and starting a timer in response to detecting the first data unit. The data missing event is detected each time the timer expires before a new data unit is detected on the communication path.

[0480] In many embodiments, the method includes resetting the timer whenever a new data unit is detected on the communication path before expiration of the timer.

[0481] In many embodiments, an energy system includes an array of cascaded modules configured to output a voltage waveform and / or a current waveform to a load. Each module includes an energy source, a switch circuit system, and a local control device. Each module has an identifier. The energy system includes a master control device communicatively coupled to each local control device via a communication path. The master control device is configured to: send a control information data element and a synchronization signal to the local control device via the communication path, and adjust the synchronization signal to initiate a synchronization event at each local control device.

[0482] In many embodiments, the master control device is configured to adjust the synchronization signal by adjusting at least one of a duty cycle or a frequency of the synchronization signal.

[0483] In many embodiments, the local control device of each module is configured to detect the synchronization event based on the adjusted synchronization signal, and to perform a synchronization action in response to detecting the synchronization event.

[0484] In many embodiments, the local control device of each module includes a PWM controller configured to generate PWM switching signals for the switch circuit system of the module. The local control device of each module is configured to perform the synchronization action by resetting the PWM controller of the local control device.

[0485] In many embodiments, resetting the PWM controller includes resetting a PWM counter of the PWM controller.

[0486] In many embodiments, the PWM controller of each local control device includes a carrier generator that generates a carrier signal used to generate the PWM switching signal based on the PWM counter.

[0487] In many embodiments, each local control device includes a synchronization unit configured to receive a synchronization signal and detect a synchronization event based on an adjusted synchronization signal.

[0488] In many embodiments, the synchronization unit is configured to detect the synchronization event based on a voltage level of a capacitor coupled to the synchronization unit.

[0489] In many embodiments, the master control device is configured to adjust at least one of a duty cycle or a frequency of the synchronization signal during one or more cycles of the synchronization signal to increase a charge level of the capacitor.

[0490] In many embodiments, the synchronization unit is configured to detect the synchronization event in response to a voltage level of the capacitor meeting or exceeding a threshold voltage level.

[0491] In many embodiments, the synchronization unit includes a comparator configured to compare the voltage level of the capacitor with the threshold voltage level.

[0492] In many embodiments, the energy system includes a plurality of modules. Each module has an energy source and a converter. The plurality of modules are configured to receive a synchronization signal and generate synchronized output signals. The system is configured to generate an AC signal based on the superposition of the output signals from each module. The plurality of modules are configured to synchronize their output signals based on a change in the frequency of the synchronization signal.

[0493] In many embodiments, the plurality of modules are configured to perform pulse width modulation to generate the output signal. Synchronization of the pulse width modulation is based on a change in the frequency of the synchronization signal.

[0494] In many embodiments, the plurality of modules are configured to perform pulse width modulation using carrier signals with different phases and a modulated reference signal. Generation of the carrier signal is synchronized between the plurality of modules based on a change in the frequency of the synchronization signal.

[0495] In many embodiments, the plurality of modules are configured to determine when to perform a data capture event based on a change in a frequency of the synchronization signal.

[0496] In many embodiments, a method of synchronizing modules of an energy system includes receiving a synchronization signal by each module of a plurality of modules, generating, by each module of the plurality of modules, a synchronized output signal for generating an AC signal based on a superposition of output signals from each module, and synchronizing, by the plurality of modules, the output signals of the plurality of modules based on a change in a frequency of the synchronization signal.

[0497] In many embodiments, generating a synchronized output signal includes performing pulse width modulation. The synchronization of the pulse width modulation is based on a change in the frequency of the synchronization signal.

[0498] In many embodiments, generating the synchronized output signal includes performing pulse width modulation using a carrier signal with different phases and a modulated reference signal. The generation of the carrier signal is synchronized between the plurality of modules based on a change in the frequency of the synchronization signal.

[0499] In many embodiments, the method includes determining, by the plurality of modules, when to perform a data capture event based on a change in a frequency of the synchronization signal.

[0500] As used herein, the term "module" refers to one of two or more than two devices or subsystems in a system. The module can be configured to work in conjunction with other modules with similar size, function and physical arrangement (e.g., the position of electrical terminals, connectors, etc.). Modules with the same function and energy source can be configured to be the same as all other modules in the same system (e.g., rack or package) (e.g., size and physical arrangement), while modules with different functions or energy sources can be different in size and physical arrangement. Although each module can be physically removable and replaceable relative to other modules of the system (e.g., wheels on a car, or blades in an information technology (IT) blade server), this is not necessary. For example, the system can be encapsulated in a common housing that does not allow any module to be removed and replaced without disassembling the entire system. However, any and all embodiments herein can be configured so that each module can be removed and replaced in a convenient manner relative to other modules, such as without disassembling the system.

[0501] The term "master control device" is used herein in a broad sense and does not require implementation of any specific protocol, such as a master-slave relationship with any other device (eg, a local control device).

[0502] The term "output" is used in this document in a broad sense, and does not exclude acting as both an output and an input in a bidirectional manner. Similarly, the term "input" is used in this document in a broad sense, and does not exclude acting as both an input and an output in a bidirectional manner.

[0503] The terms "terminal" and "port" are used herein in a broad sense 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.

[0504] In the following, various aspects of the subject matter of the present invention are described to review and / or supplement the embodiments described so far, with emphasis on the interrelationship and interchangeability of the following embodiments. In other words, unless otherwise explicitly stated or logically unreasonable, emphasis is placed on the fact that each feature of the embodiment can be combined with each other feature.

[0505] The processing circuit system may include one or more processors, microprocessors, controllers, and / or microcontrollers, each of which may be a discrete or stand-alone chip or distributed among several different chips (and portions thereof). Any type of processing circuit system may be implemented, such as, but not limited to, a personal computing architecture (e.g., used in a desktop PC, laptop computer, tablet computer, etc.), a programmable gate array architecture, a proprietary architecture, a custom architecture, etc. The processing circuit system may include a digital signal processor, which may be implemented in hardware and / or software. The processing circuit system may execute software instructions stored on a memory, which causes the processing circuit system to take many different actions and control other components.

[0506] 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, conversion of data into a format suitable for providing to the communication circuitry (e.g., in-phase and quadrature), and / or may cause the communication circuitry to transmit data (wired or wirelessly).

[0507] The processing circuitry may also be adapted to execute an operating system and any software applications, and to perform those other functions not related to the processing of transmitted and received communications.

[0508] Computer program instructions for performing 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., and conventional procedural programming languages ​​such as the "C" programming language or similar programming languages.

[0509] The memory, storage, and / or computer-readable media may be shared by one or more of the various functional units present, or may be distributed among two or more of them (e.g., as separate memories present in different chips). The memory may also reside in its own separate chip.

[0510] If the embodiments disclosed herein include or operate in association with memory, storage, and / or computer-readable media, the memory, storage, and / or computer-readable media are non-transitory. Therefore, if the memory, storage, and / or computer-readable media are covered by one or more claims, the memory, storage, and / or computer-readable media are only non-transitory. The terms "non-transitory" and "tangible" as used herein are intended to describe memory, storage, and / or computer-readable media that do not contain propagating electromagnetic signals, but are not intended to limit the types of memory, storage, and / or computer-readable media in terms of persistent storage or otherwise. For example, "non-transitory" and / or "tangible" memory, storage, and / or computer-readable media cover volatile and non-volatile media, such as random access media (e.g., RAM, SRAM, DRAM, FRAM, etc.), read-only media (e.g., ROM, PROM, EPROM, EEPROM, flash memory, etc.) and combinations thereof (e.g., hybrid RAM and ROM, NVRAM, etc.) and variations thereof.

[0511] It should be noted that all features, elements, components, functions and steps described with respect to any embodiment provided herein are intended to be combined and replaced with features, elements, components, functions and steps from any other embodiment. If only a specific feature, element, component, function or step is described with respect to one embodiment, it should be understood that unless otherwise explicitly stated, the feature, element, component, function or step can be used with each other embodiment described herein. Therefore, this paragraph serves as the premise basis and written support for introducing claims at any time, and the claim combination is from the features, elements, components, functions and steps of different embodiments, or replaces the features, elements, components, functions and steps from another embodiment with the features, elements, components, functions and steps from one embodiment, even if the following description does not clearly indicate that such combination or replacement is possible in a particular case. It is explicitly confirmed that the explicit description of each possible combination and replacement is overly cumbersome, especially considering that a person of ordinary skill in the art will easily recognize the admissibility of each such combination and replacement.

[0512] As used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0513] 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 the embodiments are not limited to the specific forms disclosed, but on the contrary, the 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, as well as negative limitations that limit the scope by features, functions, steps or elements that are not within the scope of the invention of the claims, may be recited in the claims or added to the claims.

Claims

1. An energy system comprising: an array of cascaded modules configured to output a voltage waveform and / or a current waveform to a load, each module including an energy source, a switching circuit system, and a local control device, and each module having an identifier; and a master control device communicatively coupled to each local control device via a communication path and configured to send control information data elements to the local control devices via the communication path, wherein each control information data element comprises: a normalized reference signal for each module in the array of cascaded modules; a single identifier selected from a set of identifiers including the identifier for each module in the array of cascaded modules; and a modulation index for said module having said single identifier; and The local control device of each module is configured to: scaling the normalized reference signal of a most recently received control information data element by the modulation index of the most recently received control information data element having the identifier of the module to produce a scaled reference signal; and The scaled reference signal is used to control the switching circuitry of the module.

2. An energy system according to claim 1, wherein the master control device periodically sends the control information data elements to the local control devices according to a sequence, and the sequence uses the control information data elements to define the module order in which the updated modulation index is sent to the modules.

3. The energy system according to claim 1 or 2, wherein the local control device of each module is configured to: determining whether a selected identifier of each control information data element matches the identifier of the module; when the selected identifier of a control information data element matches the identifier of the module, the local control device of the module scales the normalized reference signal of the control information data element using the modulation index of the control information data element; and When the selected identifier of the control information data element does not match the identifier of the module, the local control device of the module scales the normalized reference signal of the control information data element using the modulation index of the most recently received control information data element having the identifier of the module.

4. An energy system according to any preceding claim, wherein the master control device comprises a controller configured to generate respective modulation indices for the modules.

5. An energy system according to any preceding claim, wherein the modulation index for at least one module in the cascaded array of modules is different from the modulation index for at least one other module in the cascaded array of modules.

6. The energy system according to claim 5 further comprises a bidirectional data path that communicatively couples each local control device to the main control device, wherein each local control device is configured to send status information for the module containing the local control device to the main control device via the bidirectional data path.

7. The energy system of claim 6, wherein the controller uses the status information received from each local control device to generate the modulation index for each module.

8. An energy system according to claim 6, wherein the status information for each module includes one or more of the following: (i) a charging state of the energy source of the module, (ii) a health state of the energy source of the module, or (iii) a temperature of the energy source of the module.

9. The energy system of claim 1, wherein the communication path comprises a serial communication path.

10. A method of controlling a voltage or a current supplied to a load, the method comprising: A control information data element is sent by a master control device through a communication path to a local control device of a cascaded module array configured to output a voltage waveform and / or a current waveform to a load, wherein each module includes an energy source, a switch circuit system, a local control device, and an identifier, and wherein each control information data element includes: a normalized reference signal for each module in the array of cascaded modules; a single identifier selected from a set of identifiers including the identifier for each module in the array of cascaded modules; and a modulation index for said module having said single identifier; scaling, by each local control device, the normalized reference signal of a most recently received control information data element by the modulation index of the most recently received control information data element having the identifier of the module to produce a scaled reference signal; and The scaled reference signal is used to control the switching circuitry of the module.

11. A method according to claim 10, wherein sending the control information data element to the local control device of the cascaded module array includes the master control device periodically sending the control information data element to the local control device according to a sequence, and the sequence uses the control information data element to define the module order in which the updated modulation index is sent to the module.

12. The method of claim 10 or 11, further comprising, for each module in the cascaded module array: determining, by the local control device of the module, whether the selected identifier of each control information data element matches the identifier of the module; scaling, by the local control device of the module, the normalized reference signal of the control information data element using the modulation index of the control information data element when the selected identifier of the control information data element matches the identifier of the module; and When the selected identifier of the control information data element does not match the identifier of the module, the normalized reference signal of the control information data element is scaled by the local control device of the module using the modulation index of the most recently received control information data element having the identifier of the module.

13. The method according to any one of claims 10 to 12, further comprising generating, by a controller of the master control device, respective modulation indices for the modules.

14. The method of any one of claims 10 to 13, wherein the modulation index for at least one module in the array of cascaded modules is different from the modulation index for at least one other module in the array of cascaded modules.

15. The method of claim 14, further comprising sending, by each local control device, status information for the modules comprising the local control device through a bidirectional data interface that communicatively couples each local control device to the master control device.

16. The method of claim 15, wherein the controller uses the status information received from each local control device to generate the modulation index for each module.

17. The method of claim 15, wherein the status information for each module comprises one or more of: (i) a charge status of the energy source of the module, (ii) a health status of the energy source of the module, or (iii) a temperature of the energy source of the module. The method of claim 10 , wherein the communication path comprises a serial communication path.

19. An energy system comprising: an array of cascaded modules configured to output a voltage waveform and / or a current waveform to a load, each module comprising an energy source, a switching circuit system, and a local control device that controls the switching circuit system based at least in part on a received normalized reference signal; as well as a master control device communicatively coupled to each local control device via a communication path and configured to send control information data elements to the local control devices via the communication path, wherein each control information data element comprises a normalized reference signal, Each local control device is configured to: detecting a first data unit on the communication path after at least a threshold duration since receipt of a previous control information data element; determining that the new control information data element has been received based on a duration that has elapsed since the first data unit was received and whether an additional data unit is received after a data reception time period including the new control information data element of the first data unit; as well as The new control information data element is processed.

20. The energy system of claim 19, wherein determining that the new control information data element has been received comprises: initiating a time for the data reception period in response to detecting the first data unit; receiving additional data units during a data element reception time period; determining whether any additional data elements were received during the post-receipt time period; as well as A determination that the new control information data element has been received is determined based on the elapse of the data element reception time period and a determination that the additional data unit was not received during the post-reception time period.

21. The energy system according to claim 19 or 20, wherein the data reception time period is based on the data size of each control information data element and the data rate of the communication path.

22. An energy system according to claim 21, wherein the data reception time period is longer than an expected time period for receiving control information data elements.

23. The energy system according to claim 22, wherein the data reception time period comprises a duration for receiving data having a data size one or two bytes larger than the data size of each control information data element.

24. The energy system of claim 21, wherein processing the new control information data element comprises operating the switching circuitry using the normalized reference signal and a modulation index for the module comprising the local control device.

25. An energy system according to claim 21, wherein the local control device is configured to operate the switching circuit system using a previously stored normalized reference signal of a previously received control information data element whenever a received control information data element is damaged or not fully received.

26. A method of controlling a voltage or a current supplied to a load, the method comprising: Sending, by the master control device, a control information data element via a communication path to a local control device of an array of cascaded modules configured to output a voltage waveform and / or a current waveform to a load, wherein each module includes an energy source, a switching circuit system, and a local control device, the local control device controlling the switching circuit system based at least in part on the received normalized reference signal; detecting, by the local control device, a first data unit on the communication path after at least a threshold duration since receipt of a previous control information data element; determining, by the local control device, that the new control information data element has been received based on a duration that has elapsed since the first data unit was received and whether an additional data unit is received after a data reception time period including the new control information data element of the first data unit; as well as The new control information data element is processed.

27. The method of claim 26, wherein determining that the new control information data element has been received comprises: initiating a time for the data reception period in response to detecting the first data unit; receiving additional data units during a data element reception time period; determining whether any additional data elements were received during the post-receipt time period; as well as A determination that the new control information data element has been received is determined based on the elapse of the data element reception time period and a determination that the additional data unit was not received during the post-reception time period.

28. The method of claim 26 or 27, wherein the data reception time period is based on a data size of each control information data element and a data rate of the communication path.

29. The method of claim 28, wherein the data reception time period is longer than an expected time period for receiving control information data elements.

30. The method of claim 29, wherein the data reception time period comprises a duration for receiving data having a data size one or two bytes larger than the data size of each control information data element.

31. The method of claim 28, wherein processing the new control information data element comprises operating the switching circuitry using the normalized reference signal and a modulation index for the module containing the local control device.

32. The method of claim 28, wherein the local control device is configured to operate the switch circuitry using a previously stored normalized reference signal of a previously received control information data element whenever a received control information data element is corrupted or incompletely received.

33. An energy system comprising: an array of cascaded modules configured to output a voltage waveform and / or a current waveform to a load, each module comprising an energy source, a switching circuit system, and a local control device that controls the switching circuit system based at least in part on a received normalized reference signal; and a master control device communicatively coupled to each local control device via a control path and a synchronization path and: Control information data elements are sent to the local control device via the control path, wherein each control information data element comprises: a normalized reference signal for each module in the cascade of modules, and a modulation index for scaling the reference signal, and A synchronization signal is sent to the local control device via the synchronization path, wherein the synchronization signal indicates when a control information data element is sent to the local control device.

34. The energy system of claim 33, wherein the local control device of each module is configured to detect the synchronization signal and to capture the control information data element in response to detecting the synchronization signal.

35. An energy system according to claim 33 or 34, wherein the master control device is configured to remove the synchronization signal after completing the transmission of the control information data element.

36. An energy system according to claim 35, wherein the local control device of each module is configured to stop capturing the control information data elements in response to detecting that the synchronization signal has been removed.

37. An energy system according to any one of claims 33 to 36, wherein sending the synchronization signal includes increasing a voltage level on a synchronization signal bus, the synchronization signal bus being coupled to the master control device and the local control device of each module in the cascaded module array.

38. The energy system of claim 37, wherein removing the synchronization signal comprises reducing the voltage level on the synchronization signal bus.

39. An energy system according to any one of claims 33 to 36, wherein each local control device is configured to wake up the module containing the local control device from a sleep mode in response to detecting the synchronization signal.

40. The energy system of claim 39, wherein the master control device is configured to send the synchronization signal in response to determining to wake up the module in the cascaded module array.

41. A method of controlling a voltage or current supplied to a load, the method comprising: A control information data element is sent by a master control device through a control path to local control devices of an array of cascaded modules configured to output a voltage waveform and / or a current waveform to a load, each module comprising an energy source, a switch circuit system, and a local control device, the local control device controlling the switch circuit system based at least in part on a received normalized reference signal, wherein the master control device is communicatively coupled to each local control device through the control path and through a synchronization path, and wherein each control information data element comprises: a normalized reference signal for each module in the cascade of modules, and a modulation index for scaling the reference signal, and A synchronization signal is sent to the local control device via the synchronization path, wherein the synchronization signal indicates when a control information data element is sent to the local control device.

42. The method of claim 41, further comprising: detecting the synchronization signal by the local control device of each module; as well as The control information data element is captured by the local control device of each module in response to detecting the synchronization signal.

43. The method of claim 41 or 42, further comprising removing, by the master control device, the synchronization signal after completing the transmission of the control information data element.

44. A method according to claim 43, wherein the local control means of each module is configured to cease acquiring the control information data elements in response to detecting that the synchronization signal has been removed.

45. The method of any one of claims 41 to 44, wherein sending the synchronization signal comprises increasing a voltage level on a synchronization signal bus coupled to the master control device and the local control device of each module in the cascaded module array.

46. ​​The method of claim 45, wherein removing the synchronization signal comprises lowering the voltage level on the synchronization signal bus.

47. A method according to any one of claims 41 to 46, wherein each local control device is configured to wake up the module including the local control device from a sleep mode in response to detecting the synchronization signal.

48. The method of claim 47, wherein sending a synchronization signal to the local control device via the synchronization path comprises sending the synchronization signal in response to determining to wake up the module in the cascaded array of modules.

49. An energy system configured to generate split-phase AC power, comprising: a first array of modules and a second array of modules, wherein each module in the first array and the second array comprises a converter coupled to an energy source, wherein, The first array is configured to generate a first AC signal between a first output and a second output of the first array, the first AC signal having a first phase angle, The second array is configured to generate a second AC signal having a second phase angle between the first output and the second output of the second array, the second phase angle being 180 degrees different from the first phase angle, and The first output of the first array is connected to a first system output terminal (L1), the first output of the second array is connected to a second system output terminal (L2), and the second outputs of the first array and the second array are connected to a third system output terminal (N).

50. The energy system of claim 49, wherein each module comprises a local control device configured to control the switching circuitry of the converter of the module based on a normalized reference signal and a modulation index.

51. The energy system of claim 50, further comprising a master control device configured to send a first control information data element to each module in the first array and to send a second control information data element to each module in the second array.

52. The energy system of claim 51, wherein each first control information data element comprises: a first normalized reference signal for each module in an array of said first array; a single first identifier selected from a set of first identifiers for the modules in the first array, wherein the set of first identifiers includes a first identifier for each module in the first array; as well as A first modulation index for the modules in the first array having the single first identifier.

53. The energy system of claim 52, wherein each second control information data element comprises: a second normalized reference signal for each module in the array of the second array; a single second identifier selected from a set of second identifiers for the modules in the second array, wherein the set of second identifiers includes a second identifier for each module in the second array; as well as A second modulation index for the modules in the second array having the single second identifier.

54. The energy system of claim 52, wherein the local control device of each module in the first array is configured to: scaling the first normalized reference signal of a most recently received first control information data element by the first modulation index of a most recently received control information data element having the identifier of the module in the first array to produce a scaled reference signal; and The scaled reference signal is used to control the switching circuitry of the converters of the modules in the first array.

55. An energy system according to claim 51, wherein the master control device periodically sends the first control information data element to each module in the first array according to a sequence, and the sequence uses the first control information data element to define the module order in which the updated modulation index is sent to the module.

56. A method of generating split-phase AC power, comprising: generating, by a first array of modules, a first AC signal between a first output and a second output of the first array, the first AC signal having a first phase angle; as well as A second AC signal having a second phase angle is generated by a second module array between a first output and a second output of the second array, the second phase angle differing by 180 degrees from the first phase angle, wherein: Each module in the first array and the second array includes a converter coupled to an energy source, and The first output of the first array is connected to a first system output terminal (L1), the first output of the second array is connected to a second system output terminal (L2), and the second outputs of the first array and the second array are connected to a third system output terminal (N).

57. The method of claim 56, wherein each module comprises a local control device configured to control switching circuitry of the converter of the module based on a normalized reference signal and a modulation index.

58. The method of claim 57, further comprising sending, by a master control device, a first control information data element to each module in the first array and a second control information data element to each module in the second array.

59. The method of claim 58, wherein each first control information data element comprises: a first normalized reference signal for each module in an array of said first array; a single first identifier selected from a set of first identifiers for the modules in the first array, wherein the set of first identifiers includes a first identifier for each module in the first array; as well as A first modulation index for the modules in the first array having the single first identifier.

60. The method of claim 59, wherein each second control information data element comprises: a second normalized reference signal for each module in the array of the second array; a single second identifier selected from a set of second identifiers for the modules in the second array, wherein the set of second identifiers includes a second identifier for each module in the second array; as well as A second modulation index for the modules in the second array having the single second identifier.

61. The method of claim 59, further comprising: scaling, by the local control device of each module in the first array, the first normalized reference signal of a most recently received first control information data element by the first modulation index of a most recently received control information data element having the identifier of the module in the first array to produce a scaled reference signal; as well as The scaled reference signal is used by the local control device of each module in the first array to control the switching circuitry of the converter of the module in the first array.

62. The method of claim 58, wherein the master control device periodically sends the first control information data element to each module in the first array according to a sequence, the sequence using the first control information data element to define the module order in which updated modulation indices are sent to the modules.

63. A method for waking up a local control device, the method comprising: determining, by a master control device communicatively coupled to the local control devices of each module in the cascaded array of modules via a synchronization path, to wake up each local control device from a sleep mode of operation; as well as In response to determining to wake up each local control device from the sleep mode of operation, a synchronization signal is sent by the master control device to a wake-up interface of each local control device via the synchronization path.

64. The method of claim 63, further comprising sending, by the master control device, a synchronization signal through the synchronization path to each local control device each time the master control device sends a control information data element to each local control device.

65. The method of claim 64, wherein the synchronization signal indicates to each local control device that the master control device is sending the control information data element.

66. The method of claim 64, further comprising sending, by the master control device to each local control device, a control information data element to each local control device through a control path communicatively coupling the master control device to each local control device.

67. The method of claim 66, wherein each control information data element comprises: a normalized reference signal for each module in the array; a single identifier selected from a set of identifiers for the modules in the array, wherein the set of identifiers includes an identifier for each module in the array; as well as A first modulation index for the module in the first array having the single identifier.

68. A method according to any one of claims 63 to 67, wherein a first purpose of the synchronization path is to indicate to each local control device when a control information data element is sent to each local control device, and a second purpose is to wake up each local control device from the sleep operating mode.

69. An energy control system comprising: a plurality of modules configured to be connected together to output a voltage waveform and / or a current waveform to a load, each module of the plurality of modules comprising an energy source, a switching circuit system, and a local control device; as well as A master control device is configured to send control information to each local control device over a communication path, wherein the control information includes reference signal information, modulated index information, and an identifier associating the modulation index information with one of the plurality of modules.

70. The energy system of claim 69, wherein the plurality of modules are arranged in a cascade array.

71. An energy system according to claim 69 or 70, wherein the control information includes control information data elements, and wherein each control information data element includes the reference signal information for all modules in a group of modules, the modulated index information for the one module, and the identifier.

72. The energy system of claim 71, wherein the local control device of each module is configured to: scaling the reference signal information of a most recently received control information data element by the modulation index information of the most recently received control information data element having the identifier of the module to produce a scaled reference signal; and The scaled reference signal is used to control the switching circuitry of the module.

73. An energy system according to any one of claims 69 to 72, wherein the master control device periodically sends the control information to the local control device according to a sequence, the sequence defining the module order in which updated modulation index information is sent to the modules.

74. An energy system according to any one of claims 69 to 73, wherein the local control device of each module is configured to: determining whether the identifier matches an identifier of the module; When the identifier matches the identifier of the module, the local control device of the module scales the reference signal information using the modulation index information; and When the identifier does not match the identifier of the module, the local control device of the module scales the reference signal information using previously stored modulation information for the module.

75. An energy system according to any one of claims 69 to 74, wherein the master control device includes a controller configured to generate corresponding modulation index information for the modules.

76. A method of controlling a voltage or current supplied to a load, the method comprising: The main control device sends control information to each local control device of a plurality of modules through a communication path, wherein the plurality of modules are configured to be connected together to output a voltage waveform and / or a current waveform to a load, wherein: Each module of the plurality of modules includes an energy source, a switching circuit system, and the local control device, and The control information includes reference signal information, modulated index information, and an identifier associating the modulation index information with one of the plurality of modules.

77. The method of claim 76, wherein the plurality of modules are arranged in a cascade array.

78. A method according to claim 76 or 77, wherein the control information includes control information data elements, and each control information data element includes the reference signal information for all modules in a group of modules, the modulation index information for the one module, and the identifier.

79. The method of claim 78, further comprising: scaling, by each local control device, the reference signal information of a most recently received control information data element by the modulation index information of the most recently received control information data element having the identifier of the module to produce a scaled reference signal; as well as The scaled reference signal is used by each local control device to control the switching circuitry of the module.

80. The method of any one of claims 76 to 79, wherein the master control device periodically sends the control information to the local control device according to a sequence, the sequence defining the order of modules in which updated modulation index information is sent to the modules.

81. The method of any one of claims 76 to 80, further comprising: determining, by each local control device, whether the identifier matches an identifier of the module; scaling the reference signal information using the modulation index information by the local control device when the identifier matches the identifier of the module; as well as When the identifier does not match the identifier of the module, the reference signal information is scaled by the local control device using previously stored modulation information for the module.

82. A method according to any one of claims 76 to 81, wherein the master control device includes a controller configured to generate corresponding modulation index information for the modules.

83. A method of synchronizing modules of an energy system, the method comprising: generating a synchronization signal by a master control device communicatively coupled to the local control device of each module; The master control device sends the synchronization signal to each local control device; adjusting, by the master control device, the synchronization signal to initiate a synchronization event, the adjustment comprising adjusting at least one of a duty cycle or a frequency of the synchronization signal; detecting, by each local control device, the synchronization event based on the adjusted synchronization signal; as well as A synchronization action is performed by each local control device in response to detecting the synchronization event.

84. The method of claim 83, wherein performing the synchronization action comprises resetting a pulse width modulation (PWM) controller of the module, wherein the PWM controller is configured to generate a PWM switching signal for a converter of the module.

85. The method of claim 84, wherein resetting the PWM controller comprises resetting a PWM counter of the PWM controller.

86. The method of claim 85, wherein the PWM controller comprises a carrier generator that generates a carrier signal for generating the PWM switching signal based on the PWM counter.

87. The method of any one of claims 83 to 86, wherein generating the synchronization signal comprises generating a regular synchronization signal having a regular frequency and amplitude.

88. The method of claim 87, further comprising detecting a data capture event based on the regular synchronization signal.

89. The method of claim 88, further comprising capturing data from a path or link communicatively coupling the master control device to the local control device in response to detecting the data capture event.

90. The method of any one of claims 83 to 89, wherein detecting the synchronization event comprises: applying the synchronization signal to a capacitor; comparing the voltage of the capacitor to a threshold voltage level; as well as The synchronization event is detected when the voltage of the capacitor is greater than or equal to the threshold voltage level.

91. The method of claim 90, wherein adjusting the synchronization signal comprises reducing a frequency of the synchronization signal.

92. A method of synchronizing modules of an energy system, the method comprising: detecting, by the local control device, a data loss event on a communication path communicatively coupling the master control device to the local control device; as well as In response to detecting the data missing event, a synchronization action is performed.

93. The method of claim 92, wherein performing the synchronization action comprises resetting a pulse width modulation (PWM) controller of the module, wherein the PWM controller is configured to generate a PWM switching signal for a converter of the module.

94. The method of claim 93, wherein resetting the PWM controller comprises resetting a PWM counter of the PWM controller.

95. The method of claim 94, wherein the PWM controller comprises a carrier generator that generates a carrier signal for generating the PWM switching signal based on the PWM counter.

96. The method of any one of claims 92 to 95, wherein detecting the data missing event comprises: detecting a first data unit on the communication path after at least a threshold duration since receipt of a previous data element; starting a timer in response to detecting the first data unit; The data missing event is detected each time the timer expires before a new data unit is detected on the communication path.

97. The method of claim 96, further comprising resetting the timer whenever a new data unit is detected on the communication path before expiration of the timer.

98. An energy system comprising: an array of cascaded modules configured to output a voltage waveform and / or a current waveform to a load, each module including an energy source, a switching circuit system, and a local control device, and each module having an identifier; and a master control device communicatively coupled to each local control device via a communication path and configured to: sending control information data elements and synchronization signals to the local control device via the communication path; and The synchronization signal is adjusted to initiate a synchronization event at each local control device.

99. The system of claim 98, wherein the master control device is configured to adjust the synchronization signal by adjusting at least one of a duty cycle or a frequency of the synchronization signal.

100. The system of claim 98 or 99, wherein the local control device of each module is configured to detect the synchronization event based on the adjusted synchronization signal, and to perform a synchronization action in response to detecting the synchronization event.

101. The system of claim 100, wherein: The local control device of each module includes a PWM controller configured to generate PWM switching signals for the switching circuit system of the module; and The local control device of each module is configured to perform the synchronization action by resetting the PWM controller of the local control device.

102. The system of claim 101, wherein resetting the PWM controller comprises resetting a PWM counter of the PWM controller.

103. The system of claim 102, wherein the PWM controller of each local control device comprises a carrier generator that generates a carrier signal for generating the PWM switching signal based on the PWM counter.

104. The system of any one of claims 98 to 103, wherein each local control device comprises a synchronization unit configured to receive the synchronization signal and detect a synchronization event based on the adjusted synchronization signal.

105. The system of claim 104, wherein the synchronization unit is configured to detect the synchronization event based on a voltage level of a capacitor coupled to the synchronization unit.

106. A system according to claim 105, wherein the master control device is configured to adjust at least one of the duty cycle or frequency of the synchronization signal within one or more cycles of the synchronization signal to increase the charge level of the capacitor.

107. The system of claim 106, wherein the synchronization unit is configured to detect the synchronization event in response to the voltage level of the capacitor meeting or exceeding a threshold voltage level.

108. The system of any one of claims 107, wherein the synchronization unit comprises a comparator configured to compare the voltage level of the capacitor with the threshold voltage level.

109. An energy system comprising a plurality of modules, each module having an energy source and a converter, wherein the plurality of modules are configured to receive a synchronization signal and generate a synchronized output signal, the system being configured to generate an AC signal based on the superposition of the output signals from each module, wherein the plurality of modules are configured to synchronize their output signals based on a change in the frequency of the synchronization signal.

110. The system of claim 109, wherein the plurality of modules are configured to perform pulse width modulation to generate the output signal, wherein synchronization of the pulse width modulation is based on the change in the frequency of the synchronization signal.

111. A system according to claim 109 or 110, wherein the plurality of modules are configured to perform pulse width modulation using a carrier signal and a modulated reference signal with different phases, wherein the generation of the carrier signal is synchronized between the plurality of modules based on the change in the frequency of the synchronization signal.

112. The system of any one of claims 109 to 111, wherein the plurality of modules are configured to determine when to perform a data capture event based on the change in the frequency of the synchronization signal.

113. A method of synchronizing modules of an energy system, the method comprising: receiving a synchronization signal by each module of the plurality of modules; generating a synchronized output signal from each module of the plurality of modules for use in generating an AC signal based on a superposition of the output signals from each module; as well as The output signals of the plurality of modules are synchronized by the plurality of modules based on a change in a frequency of the synchronization signal.

114. The method of claim 113, wherein generating the synchronized output signal comprises performing pulse width modulation, wherein synchronization of the pulse width modulation is based on the change in the frequency of the synchronization signal.

115. A system according to claim 113 or 114, wherein generating the synchronized output signal includes performing pulse width modulation using a carrier signal and a modulated reference signal with different phases, wherein the generation of the carrier signal is synchronized between the multiple modules based on the change in the frequency of the synchronization signal.

116. The method of any one of claims 113 to 116, further comprising determining, by the plurality of modules, when to perform a data capture event based on the change in the frequency of the synchronization signal.

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