Flexible battery system for vehicle

Abstract

To provide new types of battery systems and / or architectures that function within a framework or constraints of new vehicle designs and / or configurations and that also improve some aspect of the vehicle's use and / or management.SOLUTION: Processing for configuring a plurality of batteries which supply power to a plurality of motors in a vehicle comprises receiving a configuration instruction associated with configuring a plurality of batteries which supply power to a plurality of motors in a vehicle. The batteries are configured as specified by the configuration instruction, where the batteries are configured in a plurality of configurations, including: a first configuration where at least some of the batteries are electrically connected in parallel; and a second configuration where at least some of the batteries are electrically connected in series.SELECTED DRAWING: Figure 2

Description

[Background technology]

[0001] New types of battery-powered vehicles are being developed with new designs and / or configurations. For example, Kitty Hawk has developed a battery-powered multicopter that can take off and / or land on water as needed. New types of battery systems and / or architectures are desired that work within the framework or constraints of such new vehicle designs and / or configurations and that further improve certain aspects of vehicle utilization and / or management. [Brief description of the drawings]

[0002] Various embodiments of the invention are disclosed in the following detailed description and the accompanying drawings.

[0003] [Figure 1A] 1 is a perspective view of an embodiment of a battery-powered vehicle;

[0004] [Figure 1B] 1 is a side view of an embodiment of a battery-powered vehicle.

[0005] [Diagram 2] 4 is a flow chart illustrating one embodiment of a process for configuring multiple batteries to power multiple motors in a vehicle.

[0006] [Diagram 3] FIG. 1 illustrates an embodiment of a flexible battery system.

[0007] [Figure 4] FIG. 1 illustrates an embodiment of a flexible battery system with a parallel battery and motor configuration.

[0008] [Diagram 5]4 is a flow chart illustrating one embodiment of a process for configuring multiple batteries, such as by connecting at least some of the batteries in parallel, in response to configuration commands generated in anticipation of vehicle takeoff.

[0009] [Figure 6] FIG. 1 illustrates an embodiment of a flexible battery system with batteries in series.

[0010] [Figure 7] 4 is a flow chart illustrating one embodiment of a process for configuring multiple batteries, such as by connecting at least some of the batteries in series, in response to configuration instructions generated in anticipation of charging the multiple batteries.

[0011] [Figure 8] FIG. 1 illustrates an embodiment of a flexible battery system in which defective batteries are isolated.

[0012] [Figure 9] 4 is a flow chart illustrating one embodiment of a process for configuring multiple batteries, such as by isolating a failed battery.

[0013] [Figure 10A] FIG. 1 illustrates an embodiment of a flexible battery system in which one group of batteries are connected in series and another group of batteries are connected in parallel.

[0014] [Figure 10B] FIG. 1 illustrates an embodiment of a first set of one or more motors powered by a first set of batteries and a second set of one or more motors powered by a second set of one or more batteries.

[0015] [Figure 11]1 is a flow chart illustrating one embodiment of a process for configuring a first set of one or more motors powered by a first set of batteries and a second set of one or more motors powered by a second set of one or more batteries. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] The present invention may be embodied in various forms, including as a process, an apparatus, a system, a composition of matter, a computer program product embodied on a computer-readable storage medium, and / or a processor configured to execute instructions stored in and / or provided by a memory coupled to the processor. These embodiments or any other form the present invention may take may be referred to herein as techniques. In general, the order of steps of a disclosed process may be altered within the scope of the present invention. Unless otherwise noted, components such as a processor or memory described as configured to perform a task may be implemented as general components temporarily configured to perform the task at a time, or as specific components manufactured to perform the task. As used herein, the term "processor" refers to one or more devices, circuits, and / or processing cores configured to process data, such as computer program instructions.

[0017] A detailed description of one or more embodiments of the present invention will now be given with reference to the drawings illustrating the principles of the present invention. The present invention will be described in connection with such embodiments, but is not limited to any of them. The scope of the present invention is limited only by the claims, and the present invention includes many alternatives, modifications, and equivalents. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. These details are for the purpose of example, and the present invention may be practiced according to the claims without some or all of these specific details. For simplicity, technical matters well known in the art related to the present invention have not been described in detail so as not to unnecessarily obscure the present invention.

[0018] Various embodiments of a flexible battery system for use in or by a vehicle are described herein. In some embodiments, a configuration instruction is received (e.g., by a battery configuration controller) associated with configuring a plurality of batteries to power a plurality of motors in a vehicle. The plurality of batteries are configured as specified by the configuration instruction, where the plurality of batteries can be configured in a plurality of configurations including: (1) a first configuration in which at least a portion of the plurality of batteries are electrically connected in parallel; and (2) a second configuration in which at least a portion of the plurality of batteries are electrically connected in series. In some examples, all of the motors in the vehicle are powered by the entire set of batteries. Alternatively, one set of motors may be powered by one set of batteries and another set of motors may be powered by another set of batteries. As described in more detail below, various configurations may be useful and / or beneficial in various situations.

[0019] FIG. 1A is a perspective view of one embodiment of a battery-powered vehicle. In the illustrated example, a multicopter (100a) is a battery-powered vehicle that can take off and land on water if desired. The multicopter has two floats or floats (102a) that are hollow and provide sufficient water displacement to allow the multicopter to have positive buoyancy and float on water. Alternatively, the multicopter can take off or land on solid ground if desired.

[0020] FIG. 1B is a side view of one embodiment of a battery-powered vehicle. FIG. 1B continues the example of FIG. 1A. In this example, each float (102b) in the vehicle (100b) is used to hold five batteries (104). This design choice (housing the batteries in the floats (102b) rather than in the fuselage (106)) was made in part because it allows for shorter electrical connections to the motor (108), which are distributed at the top of the floats (102b) and the distal end of the boom (110). It also allows for a recovery system (e.g., one or more parachutes) to be housed behind the cockpit in the fuselage (106).

[0021] The design choice of utilizing multiple small batteries rather than a single large battery also works well for vehicles with limited access to the float's interior. To prevent water ingress into the float (as well as other water-sensitive electrical components such as the printed circuit boards that control the motors), access to the float's interior is restricted to three access ports (112) at the top of the float. These relatively small access ports make it easier to insert multiple small batteries than a single large battery.

[0022] In older versions of this vehicle, each battery (104) was paired with a corresponding motor (108) such that each battery only powered one battery and each motor was only powered by one battery. However, as described in more detail below, flexible or configurable battery systems (e.g., batteries and / or motors can be electrically connected in various ways) may be desirable for charging purposes, safety, better flight performance, etc. The following figures describe various examples of such flexible battery systems.

[0023] 2 is a flow chart illustrating an embodiment of a process for configuring multiple batteries to power multiple motors in a vehicle. For example, the ten batteries of multicopters 100a and 100b in FIG. 1A and FIG. 1B may be configured in various ways to power ten motors (e.g., 108 in FIG. 1B).

[0024] At step 200, configuration instructions associated with configuring a number of batteries to power a number of motors in a vehicle are received. In some embodiments, the configuration instructions are generated based on a state of the vehicle. For example, if the vehicle is being charged, corresponding configuration instructions (e.g., instructions such that the batteries are configured in a desired manner for charging) are sent to a controller controlling a configurable electrical connector. Alternatively, if the vehicle is being started (e.g., in anticipation of takeoff), configuration instructions corresponding to flight and / or aiding in flight performance may be sent to a controller controlling a configurable electrical connector.

[0025] In step 202, the plurality of batteries are configured as specified by the configuration instructions, where the plurality of batteries may be configured into a plurality of configurations including: (1) a first configuration in which at least a portion of the plurality of batteries are connected (e.g., electrically) in parallel; and (2) a second configuration in which at least a portion of the plurality of batteries are connected (e.g., electrically) in series. For example, when at least a portion of the batteries are connected in parallel, the (first) configuration may improve flight performance when one motor is utilizing significantly more power than the other motors. An example of this is described in more detail below.

[0026] 3 is a diagram illustrating one embodiment of a flexible battery system. For simplicity and ease of explanation, this example and several other examples described herein include only two batteries and two motors. Of course, other embodiments may include a different number of batteries and / or motors.

[0027] The battery configuration controller (300) receives configuration instructions from some other controller, such as a flight controller or a central controller (e.g., a controller that knows if the vehicle has landed and is about to be charged, if it is about to take off, etc.), and configures the electrical connectors (302) accordingly.

[0028] The positive and negative connectors (e.g., B1+, B1-, B2+, and B2-) of the batteries (304a and 304b) are connected to a configurable electrical connector (302). For example, the configurable electrical connector may include one or more switches that allow the battery connections (e.g., B1+, B1-, B2+, and B2-) to be connected in various ways (e.g., in parallel or in series). The switches in the configurable electrical connector (302) are controlled by the battery configuration controller (300).

[0029] Similarly, the positive and negative power supplies (e.g., M1PS+, M1PS-, M2PS+, and M2PS-) to the motors (306a and 306b) are connected to the configurable electrical connector (302) and may be configured in various ways using the configurable electrical connector (302). For example, the power supplies to the first and second motors (306a and 306b) may be a shared power supply (e.g., B1+ and B2+ are electrically connected and B1- and B2- are electrically connected), or the power supplies to the two motors may be electrically isolated (e.g., B1+ and B2+ are electrically isolated and B1- and B2- are electrically isolated).

[0030] Returning momentarily to step 202 of Figure 2, the first configuration (at least some of the batteries are connected in parallel) may be desirable during flight when one motor is consuming significantly more power than another motor. The following diagram shows an example of such a configuration, which may be desirable during flight to improve flight performance.

[0031] FIG. 4 illustrates an embodiment of a flexible battery system in which the batteries and motors are configured in a parallel configuration. For clarity, the battery configuration controller (300) and configurable electrical connectors (302) shown in FIG. 3 are not shown in this figure. However, it should be understood that a controller (e.g., 300 in FIG. 3) configured one or more configurable electrical connectors (e.g., 302 in FIG. 3) (such as switches) to create the configuration shown here. FIG. 4 illustrates an example of a (first) configuration in which at least a portion of the multiple batteries are electrically connected in parallel (see step 202 in FIG. 2).

[0032] The configuration shown in this figure may be desirable when one of the motors (in this example, the second motor (406)) is consuming more power than the other motor (in this example, the first motor (404)) during flight of the vehicle. For example, a propeller attached to the second motor (406) may be producing more thrust and / or spinning faster than a propeller attached to the first motor (404).

[0033] In older vehicles (not shown), a first battery (400) powers only a first motor (404) and a second battery (402) powers only a second motor (406). However, if one of the motors is draining its battery, it will be limited or otherwise constrained by the current limit or other capacity or performance limit of that (single) battery, even if the other batteries in the system are not fully utilized. For example, when the vehicle is turning or banking, some motors in the vehicle are working harder than others, and therefore some batteries will be utilized more fully than others. By connecting the batteries and motors in parallel as shown, the motors (e.g., 406) needing more power can be tolerated to an extent or limit beyond that of a single battery. For example, if each battery is connected to only one motor, the motor (406) that is driving harder will be limited to the power allowance or limit of 1 x a single battery. In the parallel arrangement shown in the figure, the power allowance limit can be increased to values ​​strictly greater than a 1× single battery (e.g., 1.1×, 1.2×, etc.). In other words, by changing the arrangement of the batteries, more power can be provided to some motors, assuming the battery capacity of the individual batteries is the same. This is desirable because it improves flight performance (e.g., banking or turning) without significantly increasing weight and / or requiring more expensive batteries.

[0034] In some embodiments, the flexible battery system is transitioned to the configuration shown in the figure (or some other similar configuration) prior to takeoff. The following figures describe this more generally and / or formally in a flow chart.

[0035] 5 is a flow chart illustrating one embodiment of a process for configuring multiple batteries, such as by connecting at least some batteries in parallel, in response to configuration commands generated in anticipation of vehicle takeoff. As with the example of FIG. 2, in some embodiments, the process is performed by some battery configuration controller (e.g., 300 of FIG. 3).

[0036] At step 500, configuration commands associated with configuring a plurality of batteries to power a plurality of motors in a vehicle are received, where the configuration commands were generated in anticipation of takeoff of the vehicle.

[0037] For example, when the vehicle is in some pre-flight state (e.g., landing, preparing for takeoff), there may be some central controller or flight controller that generates configuration instructions (e.g., instructions that the vehicle is about to take off, that at least some of the batteries should be in a parallel configuration, etc.) and sends the instructions to a battery configuration controller.

[0038] In step 502, the multiple batteries are configured as specified by configuration instructions, where the multiple batteries are capable of being configured into multiple configurations including (1) a first configuration in which at least a portion of the multiple batteries are connected in parallel, and (2) a second configuration in which at least a portion of the multiple batteries are connected in series, and in response to receiving configuration instructions generated in anticipation of the vehicle taking off, the multiple batteries are configured into the first configuration in which at least a portion of the multiple batteries are connected in parallel.

[0039] For example, as described above in FIG. 4, configuring the batteries in this manner may improve flight performance by allowing some power-hungry motors (e.g., 406 in FIG. 4) to have access to more than the power of a single battery in some cases (e.g., when other motors (e.g., 404 in FIG. 4) are consuming less power and the battery has available capacity or resources).

[0040] Returning momentarily to step 202 of Figure 2, the second configuration (wherein at least a portion of the batteries are connected in series) may be desirable when the batteries are being charged. The following diagram shows an example of such a configuration, which may be desirable during charging.

[0041] Figure 6 illustrates an embodiment of a flexible battery system in which batteries are in series. For example, a battery configuration controller 300 of Figure 3 may configure a configurable electrical connector (302), which may include one or more switches, to achieve the electrical configuration shown in the figure. As previously mentioned, the battery configuration controller (e.g., 300 of Figure 3) and at least some of the configurable electrical connectors (e.g., 302 of Figure 3) are not shown for clarity.

[0042] In this configuration, the two batteries (600 and 602) are connected in series. For example, a switch or other configurable electrical connector may be set or configured to electrically connect the negative connector (e.g., B1-) of one battery to the positive connector (e.g., B2+) of the other battery.

[0043] A charger (604) is connected in parallel to the series connected batteries (600 and 602) to charge the batteries. In this example, switches (610 and 612) in parallel with diodes (614 and 616) are placed between the charger and each motor to prevent any current flow from the charger (604) to the motors (606 and 608) during charging. In the state shown, the switches (610 and 612) are open such that the only possible path from the charger to each of the motors is through the diodes, and the directionality of the diodes prevents any current flow to the motors in this mode.

[0044] In the example of Figure 3, the switches (610 and 612 in Figure 6) and diodes (614 and 616 in Figure 6) are included in the configurable electrical connector (302 in Figure 3). The states (e.g., open and closed) of the switches (610 and 612 in Figure 6) are controlled by the battery configuration controller 300 in Figure 3.

[0045] In the example of FIG. 4, the battery configuration controller may close switches (610 and 612 in FIG. 6) to allow the batteries (400 and 402 in FIG. 4) to power the motors (404 and 406 in FIG. 4) during flight.

[0046] Configuring the batteries in a series configuration as shown in this figure is useful for charging as it reduces the cost of the charger and increases the number of commercially available chargers available. For example, in the older fixed arrangements described above where each battery only powers its corresponding motor (and the configuration cannot be changed), charging can be performed with a single charger, but there are few commercially available options and those that do exist are expensive. If the flexible battery systems described above are configured in a series configuration (e.g., see Figure 6) for charging, this increases the number of "off the shelf" charging options.

[0047] Similarly, even if a single charger could be used to charge the parallel configuration shown in FIG. 4, the higher current required would result in significantly more heat generated from the wiring and connections. This means that such a charger would require more heat-resistant (and costly) components to accommodate this. The higher current required at the lower voltage would also have a substantial impact on the weight of the wiring on the vehicle (e.g., to accommodate the higher current expected to pass through the wiring) and on the thermal performance of many propulsion system components (e.g., more expensive ones would need to be able to handle more heat). In contrast, if a flexible battery system were in a series configuration (e.g., see FIG. 6), the battery system could be charged at a higher voltage using a lower current, which is more desirable for a variety of reasons (e.g., reduced wiring weight, less expensive thermal components, etc.).

[0048] In some embodiments, configuration instructions may be generated to put the battery into this configuration in anticipation of charging. The following figures show examples of this more formally and / or generally in flow chart form.

[0049] 7 is a flow chart illustrating one embodiment of a process for configuring multiple batteries, such as by connecting at least some of the batteries in series, in response to configuration instructions generated in anticipation of charging multiple batteries. In some embodiments, the process is performed by some battery configuration controller (e.g., 300 of FIG. 3).

[0050] At step 700, configuration instructions associated with configuring a plurality of batteries to power a plurality of motors in a vehicle are received, where the configuration instructions were generated in anticipation of charging the plurality of batteries.

[0051] For example, the configuration instructions may be generated in response to detecting that any cap or cover covering the charging port has been removed, or in response to a charger (e.g., male) connector being connected or inserted into a vehicle's (e.g., female) charging port.

[0052] In step 702, the multiple batteries are configured as specified by configuration instructions, where the multiple batteries are capable of being configured into multiple configurations including (1) a first configuration in which at least a portion of the multiple batteries are connected in parallel, and (2) a second configuration in which at least a portion of the multiple batteries are connected in series, and in response to receiving configuration instructions generated in anticipation of charging the multiple batteries, the multiple batteries are configured into the second configuration in which at least a portion of the multiple batteries are connected in series.

[0053] See, for example, the configuration shown in Figure 6. As shown in the example of Figure 6, in some embodiments, a battery configuration controller (e.g., 300 of Figure 3) configures one or more switches (e.g., 610 and 612 of Figure 6) in any connection or input to the motor (e.g., 606 and 608 of Figure 6) so that no power is provided to the stopped motor when charging.

[0054] In some examples, the battery configuration controller modifies switches and / or configurable electrical connectors to electrically isolate a failed or defective battery. An example of this is provided in the following diagram.

[0055] FIG. 8 illustrates an embodiment of a flexible battery system in which a faulty battery is isolated. In the illustrated example, the vehicle is in flight. Prior to the state shown in this figure, the batteries and motors were in the configuration shown in FIG. 4. In this example, during flight, the second battery (802) fails. If the second battery remained electrically connected to the rest of the system, the good first battery (800) would send current to the faulty second battery (802) due to the low voltage of the faulty battery. However, further current to the faulty second battery (802) would simply degrade it further (e.g., heat it up further). To avoid this (or at least mitigate damage), the battery configuration controller changes the settings of the switches and / or configurable electrical connections such that the second battery is electrically isolated (i.e., no longer connected) from the rest of the system as shown in the figure. The first battery (800) remains connected to both motors (804 and 806) so that they are available for landing the vehicle.

[0056] Moreover, the configuration shown in this figure is useful because all of the motors still have access to the battery. In an older fixed configuration where each battery only powers a single corresponding motor (and the connections cannot be reconfigured), a faulty battery would result in a "motor dead" condition, as the corresponding motor (propeller) would lose its battery. Instead of having (as an example) ten operational motors (propellers), only nine motors (propellers) would be operational. In contrast, the flexible battery system described herein allows for isolating a faulty battery without losing a motor (propeller).

[0057] Another advantage of this example is that it can isolate bad batteries sooner than other systems. For example, other systems may attempt to electrically isolate bad batteries using passive elements, such as fuses (e.g., a fuse in series with each battery). When the current flowing through the fuse and battery becomes too high, the fuse blows and the battery is electrically isolated. However, in this example, a bad battery is detected or otherwise flagged if a voltage sensor (e.g., a sensor that measures the voltage of the battery) detects that a given battery has a voltage below some voltage threshold, or if a temperature sensor records a temperature above some temperature threshold.

[0058] Similarly, in some embodiments, the system may be configured to (promptly) create an open circuit around a motor having some type of fault and / or electrically isolate the motor in response to detecting a fault (e.g., in a motor controller, propulsion unit, etc.). Note that this may be accomplished without electrically isolating any batteries, if desired.

[0059] In some embodiments, there are multiple temperature sensors, including one or more external temperature sensors 810 adjacent to the battery's (metal) case or container (e.g., effective for detecting if a failed cell is one of the outermost cells near the case) and one or more internal temperature sensors 812 between layers of cells (e.g., effective for detecting if a failed cell is one of the innermost cells near the center of the layers).

[0060] Once a battery failure is detected (e.g., using temperature and / or voltage thresholds), appropriate configuration instructions are generated and sent to the battery configuration controller, and switches or other configurable electrical connectors are configured accordingly (i.e., configured to isolate the faulty battery).

[0061] The following diagram describes this more formally and / or generally in a flow chart.

[0062] 9 is a flow chart illustrating one embodiment of a process for configuring multiple batteries, such as by isolating a failed battery. In some embodiments, the process is performed by a battery configuration controller (e.g., 300 of FIG. 3).

[0063] At step 900, configuration commands associated with configuring a plurality of batteries to power a plurality of motors in a vehicle are received, where the configuration commands were generated in response to detecting a faulty battery among the plurality of batteries.

[0064] For example, a failed battery may be detected in step 900 using one or more of a voltage threshold or a temperature threshold (as described above). In some embodiments, each battery in the plurality of batteries includes an internal temperature sensor (e.g., located between a layer of cells inside the battery container) and an external temperature sensor (e.g., outside the battery container).

[0065] In step 902, the plurality of batteries are configured as specified by configuration instructions, where the plurality of batteries may be configured into a plurality of configurations including (1) a first configuration in which at least a portion of the plurality of batteries are connected in parallel, and (2) a second configuration in which at least a portion of the plurality of batteries are connected in series, and in response to receiving a configuration instruction generated in response to detecting a faulty battery, the plurality of batteries are configured into a third configuration in which the faulty battery is isolated from the other batteries of the plurality of batteries. See, e.g., FIG. 8.

[0066] Returning momentarily to FIGS. 1A and 1B, a design choice or constraint associated with the example multicopter shown in those figures is that the propellers are at a fixed angle and cannot tilt. As a result, if the multicopter were to hover in the air for an extended period of time, this would place a large strain on the two front-most motors, taking into account the vehicle's center of gravity, propeller distribution, propeller angle, etc. Conversely, during sustained high-speed forward flight of the illustrated vehicle, the rearmost motor would be most strained. In some embodiments, the flexible battery system configures the batteries and power supply to the motors as described in the manner described in the following figures to better accommodate long-term forward flight (or hovering, using a slightly different configuration).

[0067] FIG. 10A illustrates an embodiment of a flexible battery system in which one group of batteries are connected in series and another group of batteries are connected in parallel. As mentioned above, if the multicopter shown in this figure flies forward at high speed for an extended period of time, this puts a strain on the rearmost motors (only one of which is visible in this figure (e.g., 1000a)). To address this, in this example, a battery configuration controller (not shown for clarity) configures one or more switches and / or configurable electrical connectors (also not shown for clarity) to achieve the configuration shown in this figure. In some embodiments, the decision to set the system in this configuration, and the configuration change itself, is performed prior to takeoff (e.g., because it may be difficult to change the battery configuration during flight).

[0068] The first group of batteries (1002a and 1004a) are connected in series to produce a higher voltage battery (in this case twice the voltage of a single battery). The series batteries are then used to power the rearmost motor (1002a, for example, left or right). The motor is powered at twice the voltage of a single battery.

[0069] The remaining batteries (1006a, 1008a, and 1010a) are used to collectively power the four motors (1012a, 1014a, 1016a, and 1018a) from the front of that side of the vehicle. Because the batteries in this group are connected in parallel, the voltage supplied to the four motors is 1x the voltage of a single battery, rather than 2x.

[0070] Returning momentarily to Figure 3, note that the power supply lines (e.g., M1PS+, M1PS-, M2PS+, and M2PS-) to the motors (306a and 306b) exit from the configurable electrical connector (302). This allows a system to have one set of motors (1000a in Figure 10A) powered by one set of batteries (e.g., series connected batteries 1002a and 1004a in Figure 10A) and another set of motors (e.g., 1012a, 1014a, 1016a, and 1018a in Figure 10A) powered by another set of batteries (e.g., parallel batteries 1006a, 1008a, and 1010a in Figure 10A).

[0071] The diagram below shows the electrical connections more clearly.

[0072] Figure 10B illustrates an embodiment of a first set of one or more motors powered by a first set of batteries and a second set of one or more motors powered by a second set of one or more batteries. Figure 10B continues the example of Figure 10A and more clearly shows the electrical connections in Figure 10A.

[0073] As mentioned above, the two batteries (1002b and 1004b) are configured in series with each other, and the series-connected battery is used to power the rearmost motor (1000b) when the multicopter is in forward flight mode at high speed for extended periods of time. The advantage of this arrangement is that as a result of the higher voltage of the series-connected batteries (1002b and 1004b), less current needs to be supplied to the motor (1000b), and thus less heat is generated by the motor.

[0074] The other three batteries (1006b,...,1010b) are connected in parallel in another electrically independent part of the system, which powers the other four motors (1012b,...,1018b).

[0075] In some embodiments, the motor (1000b), motor controller, and / or propellers are designed to benefit from series-connected batteries (1002b and 1004b). More specifically, a static motor and propeller combination (i.e., not designed to utilize 1× to 2× voltage steps) does not benefit in terms of current draw. The required thrust dictates the required torque (through the propeller design), and the torque requirements dictate the required current (through the motor design). Thus, the three-phase current (0°, 120°, 240° phases) supplied to the motor remains the same, but the current in the DC lines supplying the motor controller decreases proportionately with the increase in voltage.

[0076] In contrast, in a dynamic motor and / or configurable motor and motor controller combination, the torque constant of the motor can be changed dynamically. For example, this can be done with a 6-phase motor (e.g., 0°, 60°, 120°, ...) and a motor controller with an appropriate control strategy. This reduces the currents and therefore the thermal stresses on the DC lines, the motor controller, and the 3-phase lines.

[0077] In one application, the flexible battery system is configured as shown in Figure 4. For example, when the vehicle is in operation, transient or temporary surges due to the motor (e.g., surges when the vehicle performs a bank or other maneuver) may be better met by the configuration shown in Figure 4, where all of the batteries and motors are in parallel with each other in a single electrical group.

[0078] In contrast, the configuration shown in Figures 10A and 10B may be more appropriate when the demand on a single motor is sustained. In one example, it is known in advance that in high winds, a particular motor will work harder to maintain a stationary position during hovering, and the vehicle will hover more during the next flight. The example multicopter collects real-time conditions (e.g., wind speed) and compares it to the intended direction and / or speed (e.g., if the flight is autonomous). Depending on the predicted load in live conditions, the system may be configured (e.g., prior to flight) such that the motor with the highest predicted load is configured to have the batteries in series.

[0079] In some other embodiments, the switch or configuration change is made in flight: Similar to the above, real-time conditions such as wind speed and / or desired vehicle speed, altitude, and / or thrust may be measured, and the model uses that information to predict which motor will require more power (e.g., given sustained high winds) and reconfigures the system accordingly before reaching maximum power draw from that motor.

[0080] The following diagram describes the above example more generally and / or formally in a flow chart.

[0081] 11 is a flow chart illustrating one embodiment of a process for configuring a first set of one or more motors to be powered by a first set of batteries and a second set of one or more motors to be powered by a second set of one or more batteries. As with the above example, the process described below may be performed by a battery configuration controller.

[0082] At step 1100, configuration instructions associated with configuring multiple batteries to power multiple motors in a vehicle are received. For example, this configuration shown in Figures 10A and 10B may be useful when a multicopter is attempting to hover in the air for an extended period of time. In some embodiments, appropriate configuration instructions are generated when the vehicle has been hovering for more than a certain amount of time (i.e., a threshold time).

[0083] In step 1102, the plurality of batteries are configured as specified by the configuration instructions, where the plurality of batteries are capable of being configured into a plurality of configurations including: (1) a first configuration in which at least a portion of the plurality of batteries are connected in parallel, and (2) a second configuration in which at least a portion of the plurality of batteries are connected in series.

[0084] For example, the positive and negative battery connectors (e.g., B1+, B1-, B2+, and B2-) are connected to configurable electrical connector 302 in FIG. 3, so that switches or other connectors within that block can be set or configured to achieve the desired series and / or parallel battery connections.

[0085] In step 1104, the multiple motors are configured as specified by the configuration instructions, where the multiple motors can be configured in a configuration where one or more motors of a first set of the multiple motors are powered by one or more batteries of a first set of the multiple batteries and one or more motors of a non-overlapping second set of the multiple motors are powered by one or more batteries of a non-overlapping second set of the multiple batteries.

[0086] As mentioned above, in some embodiments, the first set of batteries (powering the first set of motors) is in a first configuration in which at least a portion of the batteries are connected in parallel in step 1104. See, for example, parallel batteries 1006b-1010b in FIG. 10B. The second set of batteries (powering the second set of motors) may similarly be in a second configuration in which at least a portion of the batteries are connected in series. See, for example, series batteries 1002b and 1004b in FIG. 10B.

[0087] In some embodiments, in response to receiving a configuration command generated in response to the time associated with the vehicle being in hover mode exceeding a time threshold, the battery configuration controller configures the multiple batteries in a configuration in which a first set of motors are powered by a first set of batteries and a non-overlapping second set of motors are powered by a non-overlapping second set of batteries, step 1104 in FIG. 11 .

[0088] Similarly, in some embodiments, in response to receiving a configuration command generated in response to a time associated with the vehicle being in forward flight mode with the vehicle speed exceeding a speed threshold exceeding a time threshold (e.g., the vehicle has been flying faster than the speed threshold for longer than the time threshold), the battery configuration controller configures the multiple batteries in a configuration in which a first set of motors are powered by a first set of batteries and a non-overlapping second set of motors are powered by a non-overlapping second set of batteries, at step 1104 in FIG. 11 .

[0089] Although the above embodiments have been described in some detail for ease of understanding, the invention is not limited to the details provided. There are many alternative ways of implementing the invention. The disclosed embodiments are illustrative and are not intended to be limiting.

Claims

1. 1. A system comprising: a plurality of batteries for powering a plurality of motors in the vehicle; a battery configuration controller; Equipped with The battery configuration controller includes: receiving configuration instructions associated with configuring the plurality of batteries; configured to configure the plurality of batteries as specified by the configuration instructions; The system, wherein the plurality of batteries are capable of being configured in a plurality of configurations including: (1) a first configuration in which at least a portion of the plurality of batteries are electrically connected in parallel; and (2) a second configuration in which at least a portion of the plurality of batteries are electrically connected in series.

2. 2. The system of claim 1, the configuration instructions are generated in anticipation of takeoff of the vehicle; The battery configuration controller, in response to receiving the configuration command generated in anticipation of takeoff of the vehicle, configures the plurality of batteries to the first configuration in which at least a portion of the plurality of batteries are connected in parallel.

3. 2. The system of claim 1, the configuration instructions are generated in anticipation of charging the plurality of batteries; The battery configuration controller, in response to receiving the configuration command generated in anticipation of charging the plurality of batteries, configures the plurality of batteries into the second configuration in which at least a portion of the plurality of batteries are connected in series.

4. 2. The system of claim 1, The configuration instructions are generated in response to detecting a faulty battery among the plurality of batteries; The battery configuration controller, in response to receiving the configuration command generated in response to detecting the faulty battery, configures the plurality of batteries to a third configuration in which the faulty battery is isolated from other batteries of the plurality of batteries.

5. 2. The system of claim 1, The configuration instructions are generated in response to detecting a faulty battery among the plurality of batteries; The failed battery is detected using one or more of a voltage threshold or a temperature threshold; The battery configuration controller, in response to receiving the configuration command generated in response to detecting the faulty battery, configures the plurality of batteries to a third configuration in which the faulty battery is isolated from other batteries of the plurality of batteries.

6. 2. The system of claim 1, The configuration instructions are generated in response to detecting a faulty battery among the plurality of batteries; The failed battery is detected using one or more of a voltage threshold or a temperature threshold; each battery of the plurality of batteries includes an internal temperature sensor and an external temperature sensor; The battery configuration controller, in response to receiving the configuration command generated in response to detecting the faulty battery, configures the plurality of batteries to a third configuration in which the faulty battery is isolated from other batteries of the plurality of batteries.

7. 2. The system of claim 1, wherein the battery configuration controller is further configured to configure the plurality of motors as specified by the configuration instructions, wherein the plurality of motors are configurable in a configuration in which one or more motors of a first set of the plurality of motors are powered by one or more batteries of a first set of the plurality of batteries and one or more motors of a non-overlapping second set of the plurality of motors are powered by one or more batteries of a second set of the plurality of batteries.

8. 2. The system of claim 1, the battery configuration controller is further configured to configure the plurality of motors as specified by the configuration instructions, the plurality of motors being configurable in a configuration in which one or more motors of a first set of the plurality of motors are powered by one or more batteries of a first set of the plurality of batteries and one or more motors of a second non-overlapping set of the plurality of motors are powered by one or more batteries of a second non-overlapping set of the plurality of batteries; the first set of batteries supplying power to the first set of motors is in the first configuration in which at least some of the batteries are connected in parallel; the second set of batteries powering the second set of motors is in the second configuration in which at least a portion of the plurality of batteries are connected in series.

9. 2. The system of claim 1, the battery configuration controller is further configured to configure the plurality of motors as specified by the configuration instructions, the plurality of motors being configurable in a configuration in which one or more motors of a first set of the plurality of motors are powered by one or more batteries of a first set of the plurality of batteries and one or more motors of a second non-overlapping set of the plurality of motors are powered by one or more batteries of a second non-overlapping set of the plurality of batteries; In response to receiving a configuration command generated in response to a time associated with the vehicle being in a hover mode exceeding a time threshold, the battery configuration controller configures the plurality of batteries into the configuration in which the first set of motors are powered by the first set of batteries and the non-overlapping second set of motors are powered by the non-overlapping second set of batteries.

10. 2. The system of claim 1, the battery configuration controller is further configured to configure the plurality of motors as specified by the configuration instructions, the plurality of motors being configurable in a configuration in which one or more motors of a first set of the plurality of motors are powered by one or more batteries of a first set of the plurality of batteries and one or more motors of a second non-overlapping set of the plurality of motors are powered by one or more batteries of a second non-overlapping set of the plurality of batteries; In response to receiving a configuration command generated in response to a time associated with the vehicle being in a forward flight mode exceeding a time threshold with the vehicle speed exceeding a speed threshold, the battery configuration controller configures the plurality of batteries into the configuration in which the first set of motors are powered by the first set of batteries and the non-overlapping second set of motors are powered by the non-overlapping second set of batteries.

11. 1. A method comprising: receiving configuration instructions associated with configuring a plurality of batteries to power a plurality of motors in a vehicle; configuring the plurality of batteries as specified by the configuration instructions; Equipped with The method, wherein the plurality of batteries are capable of being configured into a plurality of configurations including: (1) a first configuration in which at least a portion of the plurality of batteries are electrically connected in parallel; and (2) a second configuration in which at least a portion of the plurality of batteries are electrically connected in series.

12. 12. The method of claim 11, the configuration instructions are generated in anticipation of takeoff of the vehicle; responsive to receiving the configuration command generated in anticipation of takeoff of the vehicle, the plurality of batteries are configured into the first configuration in which at least a portion of the plurality of batteries are connected in parallel.

13. 12. The method of claim 11, the configuration instructions are generated in anticipation of charging the plurality of batteries; responsive to receiving the configuration command generated in anticipation of charging the plurality of batteries, the plurality of batteries are configured into the second configuration in which at least a portion of the plurality of batteries are connected in series.

14. 12. The method of claim 11, The configuration instructions are generated in response to detecting a faulty battery among the plurality of batteries; in response to receiving the configuration command generated in response to detecting the faulty battery, the plurality of batteries are configured into a third configuration in which the faulty battery is isolated from other batteries of the plurality of batteries.

15. 12. The method of claim 11, The configuration instructions are generated in response to detecting a faulty battery among the plurality of batteries; The failed battery is detected using one or more of a voltage threshold or a temperature threshold; in response to receiving the configuration command generated in response to detecting the faulty battery, the plurality of batteries are configured into a third configuration in which the faulty battery is isolated from other batteries of the plurality of batteries.

16. 12. The method of claim 11, The configuration instructions are generated in response to detecting a faulty battery among the plurality of batteries; The failed battery is detected using one or more of a voltage threshold or a temperature threshold; each battery of the plurality of batteries includes an internal temperature sensor and an external temperature sensor; in response to receiving the configuration command generated in response to detecting the faulty battery, the plurality of batteries are configured into a third configuration in which the faulty battery is isolated from other batteries of the plurality of batteries.

17. 12. The method of claim 11, further comprising configuring the plurality of motors as specified by the configuration instructions; the plurality of motors can be configured in a configuration where one or more motors of a first set of the plurality of motors are powered by one or more batteries of a first set of the plurality of batteries and one or more motors of a second non-overlapping set of the plurality of motors are powered by one or more batteries of a second non-overlapping set of the plurality of batteries.

18. 12. The method of claim 11, The method further comprises configuring the plurality of motors as specified by the configuration instructions; the plurality of motors may be configured in a configuration in which one or more motors of a first set of the plurality of motors are powered by one or more batteries of a first set of the plurality of batteries and one or more motors of a second non-overlapping set of the plurality of motors are powered by one or more batteries of a second non-overlapping set of the plurality of batteries; the first set of batteries supplying power to the first set of motors is in the first configuration in which at least some of the batteries are connected in parallel; the second set of batteries powering the second set of motors is in the second configuration in which at least a portion of the plurality of batteries are connected in series.

19. 12. The method of claim 11, The method further comprises configuring the plurality of motors as specified by the configuration instructions; the plurality of motors may be configured in a configuration in which one or more motors of a first set of the plurality of motors are powered by one or more batteries of a first set of the plurality of batteries and one or more motors of a second non-overlapping set of the plurality of motors are powered by one or more batteries of a second non-overlapping set of the plurality of batteries; responsive to receiving a configuration command generated in response to a time associated with the vehicle being in a hover mode exceeding a time threshold, the plurality of batteries are configured into the configuration in which the first set of motors are powered by the first set of batteries and the non-overlapping second set of motors are powered by the non-overlapping second set of batteries.

20. 12. The method of claim 11, The method further comprises configuring the plurality of motors as specified by the configuration instructions; the plurality of motors may be configured in a configuration in which one or more motors of a first set of the plurality of motors are powered by one or more batteries of a first set of the plurality of batteries and one or more motors of a second non-overlapping set of the plurality of motors are powered by one or more batteries of a second non-overlapping set of the plurality of batteries; In response to receiving a configuration command generated in response to a time associated with the vehicle being in a forward flight mode exceeding a time threshold with the vehicle speed exceeding a speed threshold, the plurality of batteries are configured into the configuration in which the first set of motors are powered by the first set of batteries and the non-overlapping second set of motors are powered by the non-overlapping second set of batteries.

21. A computer program product embodied in a non-transitory computer-readable storage medium, comprising: computer instructions for receiving configuration instructions associated with configuring a plurality of batteries to power a plurality of motors in a vehicle; computer instructions for configuring the plurality of batteries as specified by the configuration instructions; Equipped with the plurality of batteries are capable of being configured into a plurality of configurations including: (1) a first configuration in which at least a portion of the plurality of batteries are electrically connected in parallel; and (2) a second configuration in which at least a portion of the plurality of batteries are electrically connected in series.

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