System and method to connect and disconnect one or more lithium-ion battery

Abstract

To provide a power system that prevents damage to an external battery connector in an attempt to disconnect the connector from a power system, such as an uninterruptible power supply (UPS), while high current is being provided to or from a battery.SOLUTION: A battery module 30 includes: an external system battery connector 40 to receive an external system battery connector 42, an external battery emergency power-off (EPO) terminal, and an EPO switch 48 coupled to the EPO terminal. The EPO switch is triggered by decoupling a mechanical latch 52 associated with the external system battery connector. An EPO signal is manipulated when the EPO switch is triggered to decouple a battery from the external system battery connector.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] SUMMARY This disclosure is directed to uninterruptible power supplies (UPSs) and batteries, such as lithium-ion batteries, that are used to provide backup power for UPSs. [Background technology]

[0002] Many power devices, including UPSs, employ an attached battery, including lithium-ion batteries, that connects to the UPS by an electrical (battery) connector and transfers power and signals from the UPS to and from the battery, extending the runtime of the UPS. Summary of the Invention [Problem to be solved by the invention]

[0003] In particular, when attempting to disconnect an external battery connector from a power system such as a UPS while high current is being drawn to or from the battery, electrical arcing can occur that can damage the connector. Connectors are designed to withstand arcing when connecting and disconnecting batteries, and for high current connectors, this can be a larger and more expensive connector. [Means for solving the problem]

[0004] One aspect of the present disclosure contemplates a power system including an external battery power terminal configured to receive an external battery power connector, an external battery emergency power off (EPO) terminal, and an EPO switch coupled to the EPO terminal, the EPO switch configured to be triggered by decoupling a mechanical latch associated with the external battery power connector, and an EPO signal is operated when the EPO switch is triggered to decouple a battery from the external battery power terminal.

[0005] An embodiment of the power supply system contemplates that the external battery power terminal is configured to be coupled to the battery. The battery may be a lithium ion battery. The power supply system may further include a battery management system including a microprocessor configured to control operation of a switch to decouple the battery from the external battery power terminal. The microprocessor may be configured to control the switch to decouple the battery from the external battery power terminal in response to the EPO signal. The external battery power terminal may be a battery power connector and may be configured to releasably mate with the external battery power connector. The external battery power terminal may include a positive terminal and a negative terminal, the positive and negative terminals may be configured to connect to terminals provided on the battery power connector to provide power from the power supply system. The external battery power terminal may be coupled to the battery by at least one power bus. The at least one power bus may be coupled to a switch to decouple the battery from the external battery power terminal. The switch is normally in an ON position, thereby allowing the battery to be connected to the external battery power terminal. The EPO switch can be configured to move from an ON position to an OFF position by decoupling the mechanical latch to terminate an EPO signal to a battery module microprocessor.The power system of claim 1, wherein the mechanical latch includes a manually operated fastener configured to engage the EPO switch and be extended to achieve an ON position and to disengage from the EPO switch and be retracted to achieve an OFF position.The power system can further include one or more battery frames coupled to the power system, the one or more battery frames configured to supply additional power to the power system.Each battery frame in the one or more battery frames can be coupled to the external battery power terminal, each battery frame including a battery frame connector configured to mate with an external battery frame power connector and a battery frame EPO switch coupled to a battery frame EPO terminal, the battery frame EPO terminal being coupled to the EPO terminal. The battery frame EPO switch can be configured to be triggered by decoupling a mechanical latch associated with the external battery power connector. The battery frame EPO terminal can terminate a battery frame EPO signal when the battery frame EPO switch is triggered to decouple the battery of the battery frame from the external battery power terminal. In response to the battery frame EPO signal, the battery frame module can be configured to decouple the battery frame from the external battery power terminal. The EPO signal can be interrupted when the EPO switch is triggered. The external battery power terminal and the EPO terminal can be part of a battery power connector.

[0006] Another aspect of the disclosure contemplates a computer-readable medium storing instructions that, when executed by a controller, cause the controller to perform a method of decoupling a battery from the external battery power terminal. In one embodiment, the method comprises coupling an external battery power connector to the external battery power terminal, coupling an emergency power off (EPO) switch to the external battery EPO terminal, and in response to decoupling of a mechanical latch associated with the external battery power connector, triggering the EPO switch to decouple the battery from the external battery power terminal.

[0007] The computer readable medium may further include controlling operation of a switch by a microprocessor to decouple the battery from the external battery power terminal. The switch is normally in an ON position to allow connection of the battery to the external battery power terminal. The external battery power terminal may be part of a battery power connector and may be configured to releasably mate with the external battery power connector. The external battery power terminal may include a positive terminal and a negative terminal, which may be configured to connect to terminals provided on the battery power connector to supply power from the power system. The EPO switch may be configured to move from an ON position to an OFF position by decoupling the mechanical latch to terminate an EPO signal to a battery module microprocessor.

[0008] Yet another aspect of the present disclosure contemplates a battery frame including an external battery frame power terminal configured to receive an external battery frame power connector, an external battery frame emergency power off (EPO) terminal, and a battery frame EPO switch coupled to the battery frame EPO terminal, the battery frame EPO switch configured to be triggered by decoupling a mechanical latch associated with the external battery frame power connector, and an EPO signal is operated when the EPO switch is triggered to decouple a downstream battery from a power system.

[0009] An embodiment of the battery frame may include at least one battery module coupled to an external battery frame power terminal and a battery frame EPO switch. The battery frame may be configured to disconnect at least one battery in the at least one battery module from the external battery frame power terminal in response to an EPO signal being interrupted. The battery frame may further include a lithium ion battery. The external battery frame power terminal may be part of a battery frame connector and configured to releasably mate with the external battery frame power connector. The external battery frame power terminal may include a positive terminal and a negative terminal, which may be configured to connect to terminals provided on the battery frame connector to supply power from the power system. The external battery frame power terminal may be coupled to the power system by at least one power bus. The EPO switch may be configured to move from an ON position to an OFF position by decoupling the mechanical latch to terminate an EPO signal. The mechanical latch may include a manually operated fastener configured to be extended to engage the battery frame EPO switch to achieve an ON position and retracted to disengage from the battery frame EPO switch to achieve an OFF position. The battery frame may further include at least one additional battery frame coupled to the battery frame. The at least one additional battery frame may further include an additional battery frame connector configured to mate with an additional external battery frame power connector and an additional battery frame EPO switch coupled to an additional battery frame EPO terminal. The additional battery frame EPO switch may be configured to be triggered by decoupling a mechanical latch associated with the additional external battery frame power connector.The additional battery frame EPO terminals can terminate a battery frame EPO signal when the additional battery frame EPO switch is triggered to decouple batteries in the additional battery frames from an external battery power supply terminal. In response to the additional battery frame EPO signal, at least one additional battery frame is configured to decouple an additional external battery power supply terminal from a power source.

[0010] Another aspect of the present disclosure contemplates a computer-readable medium storing instructions that, when executed by a controller, cause the controller to perform a method of decoupling a downstream battery from a power system, the method comprising: coupling an external battery-free power connector to an external battery frame power terminal; coupling an emergency power off (EPO) switch to the external battery frame EPO terminal; and, in response to decoupling of a mechanical latch associated with the external battery power connector, triggering the battery frame EPO switch to decouple the downstream battery from a power system.

[0011] The computer readable medium embodiment may further comprise disconnecting at least one battery in at least one battery module from the external battery frame power terminal in response to an interruption of the EPO signal. The external battery frame power terminal may include a positive terminal and a negative terminal configured to connect to a terminal provided on the battery frame connector for supplying power from the power system. Triggering a battery frame EPO switch to decouple a downstream battery from the power system may include moving the EPO switch from an ON position to an OFF position to terminate the EPO signal. The computer readable medium of claim 15 further comprises coupling at least one additional battery frame to the battery frame. The at least one additional battery frame may further comprise an additional battery frame connector configured to mate with an additional external battery frame power connector and an additional battery frame EPO switch coupled to the additional battery frame EPO terminal. The additional battery frame EPO switch may be configured to be triggered by decoupling a mechanical latch associated with the additional external battery frame power connector. The additional battery frame EPO terminal terminates the battery frame EPO signal when the additional battery frame EPO switch is triggered to decouple the batteries in the additional battery frame from the external battery power terminal.

[0012] Another aspect of the present disclosure contemplates a battery module including a microprocessor coupled to an emergency power off (EPO) terminal, the battery module configured to receive an EPO signal from an upstream device coupled to an EPO switch, the microprocessor configured to control a switch that decouples at least one battery in the battery module from the upstream device upon causing a change in the EPO signal.

[0013] An embodiment of the battery module further comprises coupling an upstream device to an external battery power terminal, the external battery power terminal configured to receive an external battery power connector. The external battery power terminal may be part of the battery power connector and configured to releasably mate with the external battery power connector. The external battery power terminal may include a positive terminal and a negative terminal, the positive and negative terminals may be configured to connect to terminals provided on the battery power connector. At least one battery may be coupled to the external battery power terminal. The at least one battery may be a lithium ion battery. The microprocessor may be configured to control the switch to decouple the battery from the external battery power terminal in response to a change in the EPO signal. The EPO switch may be configured to move from an ON position to an OFF position by the mechanical latch to terminate an EPO signal to the microprocessor. The battery module may further comprise a logic power source coupled to the external battery power terminal, the logic power source configured to provide power to the microprocessor. The at least one battery may include a lithium ion module having at least one lithium ion battery cell.

[0014] Another aspect of the present disclosure contemplates a computer-readable medium storing instructions that, when executed by a controller, cause the controller to perform a method of decoupling at least one battery from an upstream device. In an embodiment, the method includes coupling a microprocessor to an emergency power off (EPO) switch, configuring a battery module to receive an EPO signal from an upstream device coupled to the EPO switch, and controlling a switch having the microprocessor to decouple at least one battery in the battery module from the upstream device upon a change in the EPO signal.

[0015] An embodiment of the computer readable medium may further comprise coupling an upstream device to an external battery power terminal configured to receive an external battery power connector. The external battery power terminal may be part of a battery power connector and configured to releasably mate with the external battery power connector. The external battery power terminal may include a positive terminal and a negative terminal, the positive and negative terminals may be configured to connect to terminals provided on the battery power connector. At least one battery may be coupled to the external battery power terminal. The at least one battery may be a lithium ion battery. The computer readable medium may control the switch to decouple the battery from the external battery power terminal in response to a change in the EPO signal. The computer readable medium may further comprise moving the mechanical latch from an ON position to an OFF position by decoupling to terminate an EPO signal to a microprocessor. The computer readable medium may further comprise powering a microprocessor by a logic power source coupled to the external battery power terminal. The at least one battery may include a lithium ion module having at least one lithium ion battery cell. [Brief description of the drawings]

[0016] Various aspects of at least one embodiment are described in detail below with reference to the accompanying figures, which are not intended to be drawn to scale. The figures are included to illustrate and facilitate understanding of various aspects and embodiments, and are incorporated as part of this specification, but are not intended to define the limitations of any particular embodiment. The drawings, together with the remainder of the specification, serve to explain the principles and operation of the described and claimed aspects and embodiments. In the figures, each identical or nearly identical component that is illustrated in various figures is labeled with a like reference numeral. For simplicity of description, not every component may be labeled in every figure. [Figure 1]FIG. 1 is a block diagram of an exemplary UPS. [Diagram 2] FIG. 2 is a block diagram of a battery module according to an embodiment of the present disclosure. [Diagram 3] FIG. 1 is a block diagram of an assembly including a power supply system connected to several battery frames in an embodiment of the present disclosure. [Figure 4] FIG. 2 is a perspective view of the system battery connector prior to insertion into the power system connector. [Diagram 5] FIG. 1 is an enlarged perspective view of the system battery connector connected to the power system connector. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] The disclosure is not intended to limit the application to the details of construction and arrangement of components set forth in the following description or illustrated by the drawings. The disclosure enables and enables other embodiments to be practiced or to be carried out in various ways. Moreover, the language and terminology used herein is for purposes of description and should not be regarded as limiting. The use of "including," "comprising," "having," "containing," "involving," and similar variations thereof herein is open-ended, i.e., means "including but not limited to."

[0018] Embodiments of the present disclosure contemplate systems and methods for disconnecting batteries, such as lithium-ion batteries, from electronic devices, including but not limited to power devices such as UPS. The embodiments of the present disclosure are applicable to lithium-ion batteries and other "smart batteries" that include a microprocessor and a power device controlled by the microprocessor to open charge and discharge paths to the battery and to disconnect the battery from other batteries (so-called power disconnection).

[0019] In some embodiments, the battery contains power and other communication and control signals, as well as an additional signal sometimes referred to as an "emergency power off" (EPO) signal. The additional EPO signal may be required to safely disconnect the battery and facilitate removal of the battery or a downstream battery, which can result in a very rapid battery shutdown, opening the power disconnect, and stopping current flow to and from the battery.

[0020] In some embodiments, the battery is further configured to generate an EPO signal via a small EPO switch that is engaged by a mechanical latch mechanism. For a battery to be operational after mechanical insertion, the mechanical latch first engages the EPO switch to close, providing an EPO signal from the system to the battery. When the mechanical latch is engaged, the battery cannot be physically removed from the electronic device.

[0021] The mechanical latch is unlatched to disconnect and remove the battery and prevent disconnecting the live connector and potential arcing and connector damage. Moving the mechanical latch to the unlatched position will terminate or change the EPO signal, which opens the switch and disconnects the battery from the power system. This results in a shutdown of the battery and an end to current discharge or charging in the battery before the user can physically pull on the mechanical battery connector and battery, and results in a mechanical disconnect of the battery without any interruption in current flow and prevents any arcing.

[0022] In some embodiments, the system may include a mechanical connector, sometimes referred to as a "frame connector," that is provided to connect multiple batteries in a battery frame with the system or with other battery frames. Each battery connection that connects a group of batteries in a battery frame and power system, or connects another battery frame (frame connector) to the battery frame, includes a small EPO switch that generates an EPO signal and a mechanical latch for the frame connector. When the frame connector is engaged, the user closes the latch to mechanically secure the battery in place and to depress the EPO switch to generate an EPO signal, thereby creating a connection between the downstream battery and the battery frame and / or power system. Again, this mechanical latch prevents physical removal of the frame connector until the mechanical latch is released and the EPO switch on the frame connector is opened.

[0023] Embodiments of the present disclosure contemplate a power system having an emergency power off (EPO) terminal, an EPO switch, and an external battery power terminal configured to accept an external battery power connector. The EPO switch is triggered when the connector is disconnected, thereby causing the EPO terminal to terminate or otherwise change the EPO signal.

[0024] In some embodiments, the mechanism for disconnecting the external battery power cable from a power system such as a UPS may require an EPO switch to be depressed at least a few milliseconds before the connector can be disconnected.

[0025] In some embodiments, pressing the EPO switch can stop drawing or supplying current to all downstream batteries.

[0026] In some embodiments, during the delay between releasing the EPO switch and disconnecting the power cable, the current through the cable can drop to zero.

[0027] Thus, it can be seen that the systems and methods disclosed herein prevent disconnection of a live connector, potential arcing, and damage to the connector, thereby enabling passing qualification testing while allowing the use of smaller, less expensive connectors.

[0028] Power devices such as UPSs provide regulated and uninterrupted power to sensitive and / or demanding loads such as computer systems and other data processing systems. Known types of UPSs include online UPSs, line-interactive UPSs, and other UPSs. Online UPSs provide regulated AC power and backup AC power in the event of an interruption to the primary source of AC power. Offline UPSs do not regulate the input AC power but provide backup AC power in the event of an interruption to the primary source of AC power. Line-interactive UPSs are similar to offline UPSs in that they switch to battery power in the event of a blackout, but also include a voltage regulation mechanism, including but not limited to a multi-tap transformer that regulates the output voltage provided by the UPS.

[0029] Referring to the drawings, and in particular to FIG. 1, an on-line UPS, generally designated 10, provides conditioned power from input AC power received at input 12, and backup DC power from a backup power source 14, e.g., a battery, at output 16. UPS 10 may be configured to provide output AC power at a voltage and frequency independent of the input AC power. In some embodiments, backup power source 14 may be contained within UPS 10, while in other embodiments backup power source 14 may be external to UPS 10, and in some embodiments may include one or more lithium ion batteries. UPS 10 includes a converter 18, a DC bus 20, an inverter 22, and a controller 24 that controls converter 18 and inverter 22. DC bus 20 is coupled between converter 18 and inverter 22.

[0030] Input 12 is configured to receive input AC power having an input voltage level from an AC power source. Controller 24 is configured to monitor the input AC power received by input 12 and to operate UPS 10 in different operating modes based on the condition of the input AC power received by input 12. When the AC power provided to input 12 is acceptable, i.e., above an input power quality threshold, controller 24 operates UPS 10 in an online operating mode.

[0031] In an on-line mode of operation, AC power from input 12 is provided to converter 18. Controller 24 operates to cause converter 18 to convert the AC power to DC power and provide the DC power to DC bus 20. The DC power from DC bus 20 is provided to inverter 22. In turn, DC power from DC bus 20 is provided for charging battery 14, either directly from converter 18 or via a separate DC / DC converter, e.g., a charger. Controller 24 operates inverter 22 to convert the DC power to regulated AC power and to provide the regulated AC power to a load coupled to output 16.

[0032] When the AC power provided to input 12 is unacceptable, i.e., falls below the input power quality threshold, controller 24 causes UPS 10 to operate in a backup mode of operation. In the backup mode of operation, DC power from backup power source 14 is provided to DC bus 20. Inverter 22 receives DC power from DC bus 20 and controller 24 operates inverter 22 to convert the DC power from bus 20 to regulated AC power and to provide the regulated AC power to a load coupled to output 16.

[0033] One or more batteries 14 may be provided to provide backup power to the UPS 10. The manner in which the batteries 14 are connected to the UPS is described below.

[0034] Referring to FIG. 2, a battery module is generally designated by the reference numeral 30. The battery module 30 is configured to power an electronic device, such as the UPS 10 described with reference to FIG. 1. The battery module 30 includes a battery management system 32 having a microprocessor 34 that provides control functions and a logic power source 36 that provides power to the microprocessor 34. As shown, the battery module 30 further includes a lithium ion battery 38 that is coupled to the logic power source 36 of the battery management system 32. In one embodiment, the lithium ion battery 38 provides power to the logic power source 36 of the battery module 30. It is noted that the logic power source 36 can be powered by the lithium ion battery 38 or by an input to the battery module 30. It is understood that the battery module 30 can power a load that is generated by any type of electronic device other than the UPS 10.

[0035] In one embodiment, microprocessor 34 is a computer processor with data processing and control provided on a single integrated circuit (IC) or on several ICs. Microprocessor 34 contains the arithmetic, logic, and control circuitry necessary to perform the functions of a central processing unit (CPU). The IC can interpret and execute instructions and perform the required arithmetic operations. Microprocessor 34 is a general-purpose, clock-driven, register-based digital IC that accepts binary data, processes the data according to instructions stored in memory, and provides the results as output.

[0036] The battery module 30 further includes a connector 40 at one end of the battery module 30. The connector 40 is configured to releasably mate with an external system battery connector 42 of an electronic device. In particular, the connector 40 has a positive terminal 44 and a negative terminal 46 that are configured to connect to terminals on an electronic device to provide power from the battery module 30 to the electronic device. To prevent potential arcing and connector damage when the connector 40 of the battery module 30 is disconnected from the system battery connector of the electronic device, the battery module 30 further includes an EPO switch 48. The EPO switch 48 is connected to the microprocessor 34 by a line 50. In one embodiment, the EPO switch 48 is part of the connector 40 and is configured to be operated by a mechanical latch 52 associated with the system battery connector 42 of the electronic device when the system battery connector 42 is coupled and secured to the connector 40. This configuration arrangement means that when the system battery connector 42 of the electronic device is fixedly coupled to the connector 40 of the battery module 30, the mechanical latch 52 operates to depress or otherwise engage the EPO switch 48, thereby moving the EPO switch from the OFF position to the ON position.

[0037] In the illustrated embodiment, the battery connector terminals 44, 46 are coupled to the lithium ion battery 38 by buses 54, 56, respectively. As shown, when the system battery connector 42 of the electronic device is coupled to the connector 40 of the battery module 30, a circuit is completed providing power from the battery module to the electronic device. The bus 54 includes a power disconnect switch 58 that disconnects power from the battery 38 to the connector 40. The power disconnect switch 58 is further controlled by the microprocessor 34 via line 60. The power disconnect switch 58 is normally in an OFF position (open state), thereby preventing the battery 38 from providing power to the electronic device.

[0038] As mentioned above, the EPO switch 48 is connected to the microprocessor 34 by lines 50. Only when the EPO switch 48 is in the ON position can the power disconnect switch 58 switch from the OFF position to the ON position (closed) to provide power from the battery 38 to the electronic device. In particular, the EPO switch 48 when pressed into the ON position transmits a signal to the microprocessor 34 which in turn transmits a signal to place the power disconnect switch 58 in the ON position. As shown, the connector 40 is connected to the microprocessor 34 by lines 62 to provide further control and communication signals from the electronic device to the microprocessor 34 when the connector 40 is mated to the system battery connector 42.

[0039] In operation, when connecting the battery module 30 to an electronic device, the connector 40 of the battery module 30 and the mating system battery connector 42 are connected in the normal manner. During this connection, the power disconnect switch 58 is in the OFF position, so that the lithium-ion battery 38 is disconnected from the electronic device. An operator must manipulate the mechanical latch 52 to depress or otherwise engage the EPO switch 48, thereby moving the EPO switch 48 from the OFF position to the ON position. As described in more detail below, any type of mechanical latch 52 can be provided to accomplish actuation of the EPO switch 48, including the device shown in Figures 4 and 5.

[0040] When the EPO switch 48 is depressed by the mechanical latch 52, it generates a signal to the microprocessor 34, which in turn generates a signal to the power disconnect switch 58 to move it from an OFF position to an ON position. At this point, the lithium-ion cells 38 of the battery module 30 can supply power to the electronic device only after a secure connection is achieved between the connector 40 and the system matching connector 42.

[0041] When disconnecting the battery module 30 from the electronic device, the operator disengages the mechanical latch 52 from the EPO switch 48. The signal to the microprocessor 34 terminates. As a result, the microprocessor 34 terminates the signal to the power disconnect switch 58, causing the power disconnect switch 58 to move from the ON position to the OFF position. With the power disconnect switch 58 in the OFF position, power from the battery 38 to the electronic device is interrupted. At this point, the external system battery connector 42 of the electronic device can be safely disconnected from the connector 40 of the battery module 30. At this point, the power device 30 can be safely removed from the electronic device.

[0042] Thus, the mechanical latch 52 is unlatched to disconnect and remove the battery 38 and prevent any disconnection of the system battery connector 42. Moving the mechanical latch 52 to the unlocked position opens the EPO switch 48 and removes the EPO signal, resulting in a battery shutdown and opening of the power disconnect switch 58, stopping any discharge or charge to the battery 38 before the user physically pulls the external battery system connector 42 from the connector 40. This results in mechanical disconnection of the battery 38 without any interruption in current flow and prevents any potential arcing.

[0043] 3, in one embodiment, an assembly generally designated by reference numeral 70 includes a power system generally designated by reference numeral 72 and several battery frames, each generally designated by reference numeral 74, coupled to the power system. As shown in FIG. 3, the power system 72 of the assembly 70 connects to a battery frame 74 located downstream of the power system 72. The power system 72 of the assembly 70 includes a power bus connected to the battery frame 74 and having a positive conductor 76 and a negative conductor 78 disposed downstream of the power system 72. In the illustrated embodiment, the battery frames 74 are connected to the power system 72 in a daisy-chained parallel configuration by the power bus.

[0044] Power system 72 includes a positive terminal 80 connected to positive bus 76 and a negative terminal 82 connected to negative bus 78. Power system 72 further includes a system connector 84 coupled to terminals 80, 82, which is configured to releasably mate with terminals of an external connector 86. Power system 72 further includes an EPO switch 88 configured to be operated by a mechanical latch 90 associated with external connector 86. As will be described in more detail below, external connector 86 and system connector 84 may be any type of connector that properly mates and mechanical latch 90 may be selected to engage EPO switch 88.

[0045] The power system 72 further includes an EPO terminal configured to receive an EPO signal from the EPO switch 88 when a mechanical latch 90 of the external connector 86 is engaged. The EPO signal is configured to transmit downstream along a line 94 to the battery frame 74.

[0046] When the external connector 86 is connected to the system connector 84 of the power supply system 72 and the mechanical latch 90 is positioned to engage the EPO switch 88, the EPO switch 88 is configured to provide an EPO signal to the downstream battery frame 74. In this condition, the downstream battery frame 74 is coupled to the power supply system 72 and provides power to the power supply system 72 from the battery module associated with the battery frame 74. And when the mechanical latch 90 is operated to disengage the EPO switch 88, the EPO switch 88 is configured to terminate or otherwise change the EPO signal to the downstream battery frame 74. In this condition, the downstream battery frame 74 is decoupled from the power supply system 72 and either interrupts power or interrupts discharge from the battery module associated with the battery frame 74 to the power supply system 72. In some embodiments, the EPO signal can be terminated, or increase or decrease in voltage, or change in some other manner.

[0047] Each battery frame 74 includes several battery modules, each indicated by reference numeral 98. In the illustrated embodiment, the battery frame 74 includes four battery modules 98, each similar to the battery module 30 as described in FIG. 2. The battery modules 98 are coupled to the power bus conductors 76, 78 by lines 100, 102 and provide power to the power system 72. As described above, when the external connector 86 is connected to the system connector 84 of the power system 72 and the mechanical latch 90 is positioned to engage the EPO switch 88, the EPO switch is configured to provide an EPO signal to the downstream battery frame 74 and maintain a connection between the battery frame and the power system. When the mechanical latch 90 is operated to disengage the EPO switch 88, the EPO switch is configured to terminate or otherwise change the EPO signal to the downstream battery frame 74, thereby terminating the connection between the downstream battery frame and the power system 72. The battery frame 74 is configured to disconnect the battery frame from the power supply system 72 in response to an interruption or change in the EPO signal, thereby terminating power from the battery frame 74 to the power supply system 72 .

[0048] Each battery frame 74 further includes a battery frame connector 104 configured to releasably mate with an external battery frame connector 106. The battery frame 74 further includes a battery frame EPO switch 108 configured to be operated by a mechanical latch 110 associated with the external battery frame connector 106. As described above, the battery frame connector 104 and the external battery frame connector 106 can be any type of properly mated connector and the mechanical latch 110 can be selected to engage the battery frame EPO switch 108. The battery frame connector 104 of the battery frame 74 includes a power terminal configured to mate with the external battery frame connector 106 when the mechanical latch 110 of the external battery frame connector 106 is engaged, and an EPO terminal configured to receive an EPO signal from the battery frame EPO switch 108. The power terminal is configured to couple the battery frame 74 to a power bus. As shown, the EPO signal from the power system 72 is delivered to the battery frame EPO switch by line 94. The EPO signal from the battery frame EPO switch 108 passes by line 112 to a downstream battery frame, for example battery frame 74a.

[0049] When the external battery frame connector 106 is connected to the battery frame connector 104 of the battery frame 74 and the mechanical latch 110 is positioned to engage the battery frame EPO switch 108, the battery frame EPO switch is configured to provide an EPO signal over line 112 to a downstream battery frame, for example, the battery frame 74a. In this condition, the downstream battery frame 74a is coupled to the battery frame 74 to effect a connection between the battery module 98a associated with the downstream battery frame 74a and the battery frame 74. And when the mechanical latch 110 is positioned to disengage the battery frame EPO switch 108, the battery frame EPO switch 108 is configured to terminate or otherwise change the EPO signal to the downstream battery frame 74a. In this condition, the downstream battery frame 74a is decoupled from the battery frame 74 and the power system 72, interrupting the connection between the battery module 98a associated with the downstream battery frame 74a of the assembly 70. In some embodiments, the EPO signal can be terminated, or increased or decreased in voltage, or changed in some other way.

[0050] For example, any number of battery frames 74 can be connected to the power system 72 of the assembly 70 by the power bus (lines 76, 78). Each additional battery frame, for example, battery frame 74a, further includes an additional battery frame connector 104a configured to mate with the additional external battery frame connector 106a and an additional battery frame EPO switch 108a coupled to the additional battery frame EPO terminal. The additional battery frame EPO switch 108a is configured to be triggered by decoupling a mechanical latch 110a associated with the additional external battery frame connector 104a. The additional battery frame EPO terminal terminates the battery frame EPO signal when the additional battery frame EPO switch 108a is triggered to decouple the battery of the downstream battery frame 74a from the external battery power terminal. In response to the additional battery frame EPO signal, the additional battery frame module is configured to decouple the additional external battery power terminal from the power source.

[0051] As mentioned above, the battery frame EPO switch 108 is coupled to the EPO switch 88 of the power supply system 72 by the line 94. The EPO switch 88 of the power supply system 72 and the EPO switch 108 of the battery frame 74 are connected in parallel with each other, which means that the battery frame having the EPO switch located downstream and in the OFF position does not supply power to the upstream devices. For example, referring to FIG. 3, when the EPO switch 108 for "Battery Frame 1" is in the OFF position (open state), power from "Battery Frame N" and subsequent battery frames is cut off from the power supply system 72. Only when the EPO switch is in the ON position (closed state) can power be supplied from the battery frames 74, 74a, etc. to the power supply system 72, thereby powering the electronic devices.

[0052] Thus, for each battery connection that connects a group of battery modules within the battery frame, an EPO switch and mechanical latch must be secured for each connection to generate an EPO signal to operate the assembly. When the frame connector is engaged and securely connected to the system battery connector, the user closes the latch to mechanically secure the battery in place and to generate an EPO signal, as described above, thereby creating a connection between the battery frame and the power system. The mechanical latch prevents physical movement of the frame connector until the user releases the mechanical latch and opens the EPO switch on the frame connector.

[0053] During removal of a battery or group of batteries in a battery frame or group of battery frames, the user releases a mechanical latch, which terminates the EPO signal from all batteries that are to be mechanically disconnected. All batteries release the power disconnect before the user unplugs them to disconnect the main frame, resulting in an open large frame connector that always has zero (0) current. Furthermore, while the battery to be shut down is removed, the remaining batteries remain in the system to continue normal operation.

[0054] In another embodiment, each of the battery frames 74, 74a, etc. can be configured to include a microprocessor. In such an embodiment, the microprocessor of the battery frame 74, 74a, etc. is coupled to the EPO switch 88 of the power system 72 by line 94. The microprocessor of the battery frame 74, 74a, etc. is configured to control a switch, such as the power disconnect switch 58, to disconnect the downstream battery frame from the battery frame in response to an interruption or change in the EPO signal.

[0055] In another embodiment, the power bus (lines 76, 78) can include a switch similar to the power disconnect switch 58 and configured to disconnect the downstream battery frames 74, 74a, etc. from the external battery frame terminals. In one embodiment, the switch is normally in an ON position, allowing the downstream battery frames 74, 74a, etc. to provide power to and discharge power from the external power terminals. For example, when the battery frame EPO switch 108 moves from the ON position to the OFF position by decoupling the mechanical latch 110 from the battery frame EPO switch, the EPO signal is terminated or otherwise changed, which causes the microprocessor to deactivate the switch and interrupt the power provided by the downstream battery frame. In a particular embodiment, the mechanical latch 110 is configured to extend to engage the battery frame EPO switch 108 to achieve the ON position and retract to disengage from the battery frame EPO switch 108 to achieve the OFF position.

[0056] In one embodiment, the battery module is provided to include a microprocessor coupled to an emergency power off (EPO) terminal. In one embodiment, the battery module may be a battery module associated with a battery frame 74. The battery module is configured to receive an EPO signal from an upstream device coupled to an EPO switch, and the microprocessor is configured to control the switch to decouple one or more batteries in the battery module from the upstream data when the EPO signal changes. In an embodiment, the upstream device is coupled to an external battery power terminal, the external battery power terminal configured to receive an external battery power connector.

[0057] The external battery power terminal is part of the battery power connector and is configured to releasably mate with the external battery power connector. The external battery power terminal includes a positive terminal and a negative terminal that are configured to connect to terminals on the battery power connector when one or more batteries are coupled to the external battery power terminal. The battery power connector and the external battery power connector can be configured to carry other control and communication signals in addition to power and EPO signals.

[0058] The configuration is as follows: the microprocessor is configured to control a switch to decouple the battery from the external battery power terminal in response to a change in the EPO signal. The EPO switch is configured to move from an ON position to an OFF position with a mechanical latch to terminate the EPO signal to the microprocessor. In one embodiment, the battery module further includes a logic power source coupled to the external battery power terminal, the logic power source configured to provide power to the microprocessor.

[0059] 4 and 5, which show a system battery connector, generally designated 120, and an external connector, generally designated 122. The system battery connector 120 and the external connector 122 may be embodied in any suitable electrical connector, such as an Anderson connector, capable of delivering power from a battery to an electronic device. The type of connector shown in FIGS. 4 and 5 is a suitable high power DC connector. As shown, the system battery connector 120 includes a switch 124, such as the EPO switch described above, that is normally in an OFF position. Depressing or otherwise engaging the EPO switch changes the state of the EPO switch from the OFF position to an ON position. The external connector 122 includes a mechanical latch 126 that is configured to depress or otherwise engage the EPO switch 124 when the external connector is securely fastened to the system battery connector, thereby connecting the electronic device to the power system and / or the battery frame and / or the battery module. In one embodiment, the mechanical latch 126 includes a manually operated fastener configured to extend and retract in a conventional manner. In operation, to depress switch 124 , a user rotates manually operable fixture 126 to extend the fixture and engage EPO switch 124 .

[0060] Upon full extension, the EPO switch 124 is depressed, thereby assuming the ON position. As described above, an EPO signal is generated to the power supply system and / or battery frame microprocessor, which in turn generates a signal to the power disconnect switch, causing the power disconnect switch to move from its normal OFF position to the ON position. When this occurs, power from the battery is supplied to the load.

[0061] Various controllers, such as microprocessors 34, 96, can perform various operations detailed above. Using data stored in associated memory and / or storage devices, the controller can further execute one or more instructions stored in one or more non-transitory computer-readable media that the controller may include and / or be coupled to, resulting in data being manipulated. In some embodiments, the controller can include one or more processors or other types of controllers. In one embodiment, the controller is or includes at least one processor. In another embodiment, the controller performs at least a portion of the operations detailed above using application specific integrated circuits tailored to perform specific operations in addition to or instead of a general purpose processor. As illustrated by these examples, embodiments according to the present disclosure can perform the operations described herein using many specific combinations of hardware and software, but the disclosure is not limited to any particular combination of hardware and software components. An embodiment of the present disclosure includes a computer program product configured to perform the methods, processes and / or operations detailed above. The computer program product is not limited to any particular combination of components. Embodiments of the present disclosure may be or may include one or more controllers and / or processors configured to execute instructions to implement the methods, processes and / or operations detailed above.

[0062] An embodiment of the present disclosure contemplates a power system having an emergency power off (EPO) terminal, an EPO switch, and an external battery power terminal that receives an external power battery connector. The EPO switch disconnects the connector, thereby allowing the EPO terminal to transmit an EPO signal.

[0063] In some embodiments, the mechanism for disconnecting the external battery power cable from a power system such as a UPS may require the EPO switch to be depressed for at least a few milliseconds before the connector can be disconnected.

[0064] In some embodiments, pressing the EPO switch can stop drawing and providing current to all downstream batteries.

[0065] In some embodiments, during the delay between pressing the EPO switch and disconnecting the power cable, the current through the cable may drop to zero.

[0066] In some embodiments, the "normally ON position" is described as a closed circuit in which the switch is always in an on state during operation. For example, when a power disconnect switch is described as being in a "normally ON position," the power disconnect switch is closed, allowing current flow, and the EPO switch is present. It is understood that the system can be configured to be in a "normally OFF position" and still fall within the scope of this disclosure.

[0067] Having described at least one several embodiments, it will be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art and are intended to be part of this disclosure, and are intended to be within the scope of this disclosure. [Explanation of symbols]

[0068] 10. UPS 12 Input 14 Backup power supply 16 Output 18 Converter 20 DC Bus 22 Inverter 24 Controller 30 Battery Module 32 Battery Management System 34 Microprocessors 36 Logic Power Supply 38 Lithium-ion battery 40 Connectors 42 External system battery connector 44 Positive terminal 46 Negative terminal 48 EPO Switch 50 Line 52 Mechanical Latch 54 Bus 56 Bus 58 Power disconnect switch 60 lines 62 Line 70 Assembly 72 Power System 74 Battery Frame 74a Battery Frame 76 Positive conductor (bus) 78 Negative conductor (bus) 80 Positive terminal 82 Negative terminal 84 System Connector 86 External Connector 88 EPO Switch 90 Mechanical Latch 98 Battery Module 98a Battery Module 104 Battery frame connector 104a Battery Frame Connector 106 External Battery Frame Connector 106a External Battery Frame Connector 108 Battery Frame EPO Switch 108a Battery Frame EPO Switch 110 Mechanical Latch 110a Mechanical Latch 120 System Battery Connector 122 External Connector 124 EPO Switch 126 Mechanical latches (manually operated fasteners)

Claims

1. 1. A power supply system, comprising: an external battery power terminal configured to receive an external battery power connector; An external battery emergency power off (EPO) terminal; and an EPO switch coupled to an EPO terminal, the EPO switch configured to be triggered by decoupling a mechanical latch associated with the external battery power connector; Equipped with A power supply system, wherein an EPO signal is operated when the EPO switch is triggered to decouple a battery from the external battery power terminal.

2. 2. The power system of claim 1, wherein the external battery power terminal is configured to be coupled to the battery.

3. 2. The power system of claim 1, wherein the battery is a lithium ion battery.

4. 10. The power system of claim 1 further comprising a battery management system including a microprocessor configured to control operation of a switch that decouples the battery from the external battery power terminal.

5. 5. The power system of claim 4, wherein said microprocessor is configured to control said switch to decouple said battery from said external battery power terminal in response to said EPO signal.

6. 2. The power system of claim 1, wherein the external battery power terminal is a battery power connector and is configured to releasably mate with the external battery power connector.

7. 7. The power system of claim 6, wherein the external battery power terminals include a positive terminal and a negative terminal, the positive and negative terminals being configured to connect to terminals provided on the battery power connector to supply power from the power system.

8. 2. The power system of claim 1, wherein the external battery power terminal is coupled to the battery by at least one power bus.

9. 9. The power system of claim 8, wherein the at least one power bus is coupled to a switch that decouples a battery from the external battery power terminal.

10. 10. The power system of claim 9, wherein said switch is normally in an ON position, thereby connecting said battery to said external battery power terminal.

11. 10. The power system of claim 1, wherein the EPO switch is configured to move from an ON position to an OFF position by decoupling the mechanical latch to terminate an EPO signal to a battery module microprocessor.

12. 2. The power system of claim 1, wherein the mechanical latch includes a manually operated fixture configured to engage the EPO switch and be extended to achieve an ON position and to be retracted to disengage from the EPO switch and achieve an OFF position.

13. 10. The power system of claim 1, further comprising one or more battery frames coupled to the power system, the one or more battery frames configured to supply additional power to the power system.

14. 14. The power supply system of claim 13, wherein each battery frame in the one or more battery frames is coupled to the external battery power terminal, each battery frame including a battery frame connector configured to mate with an external battery frame power connector and a battery frame EPO switch coupled to a battery frame EPO terminal, the battery frame EPO terminal being coupled to the EPO terminal.

15. 15. The power system of claim 14, wherein the battery frame EPO switch is configured to be triggered by decoupling a mechanical latch associated with the external battery power connector.

16. 16. The power supply system of claim 15, wherein the battery frame EPO terminal terminates a battery frame EPO signal when the battery frame EPO switch is triggered to decouple the battery of the battery frame from the external battery power terminal.

17. 16. The power system of claim 15, wherein in response to the battery frame EPO signal, the battery frame module is configured to decouple the battery frame from the external battery power terminal.

18. 2. The power system of claim 1, wherein the EPO signal is interrupted when the EPO switch is triggered.

19. 2. The power system of claim 1, wherein the external battery power terminal and the EPO terminal are part of a battery power connector.

20. 1. A computer readable medium storing instructions that, when executed by a controller, cause the controller to perform a method for decoupling a battery from the external battery power terminals, the method comprising: coupling an external battery power connector to an external battery power terminal; coupling an emergency power off (EPO) switch to an external battery EPO terminal; and in response to decoupling of a mechanical latch associated with the external battery power connector, triggering the EPO switch to decouple a battery from the external battery power terminal; 1. A computer-readable medium comprising:

21. 21. The computer readable medium of claim 20, further comprising the step of controlling operation of a switch by a microprocessor to decouple the battery from the external battery power terminal.

22. 22. The computer readable medium of claim 21, wherein the switch is normally in an ON position, thereby connecting the battery to the external battery power terminal.

23. 21. The computer readable medium of claim 20, wherein the external battery power terminal is part of a battery power connector and is configured to releasably mate with the external battery power connector.

24. 24. The computer readable medium of claim 23, wherein the external battery power terminals include a positive terminal and a negative terminal, the positive and negative terminals configured to connect to terminals provided on the battery power connector to supply power from the power system.

25. 21. The computer readable medium of claim 20, wherein the EPO switch is configured to move from an ON position to an OFF position by decoupling the mechanical latch to terminate an EPO signal to a battery module microprocessor.

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