Modular energy systems that power primary and secondary loads

Abstract

Provided herein are example embodiments of systems, devices, and methods for an energy system configured to power AC and DC loads. The system can include a plurality of array segments configured to output AC signals for powering the AC loads, and an auxiliary signal converter configured to convert the AC signals to DC signals for powering the DC loads. In one embodiment, each module includes one or more energy sources and a converter including a switch circuit configured to generate an output voltage for the module.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 63 / 427,057, filed November 21, 2022, U.S. Provisional Application No. 63 / 427,063, filed November 21, 2022, and U.S. Provisional Application No. 63 / 462,876, filed April 28, 2023, all of which are incorporated by reference in their entirety for all purposes.

[0002] The subject matter described herein generally relates to systems, apparatus, and methods that enable the interconnection and control of modules in a modular energy system to power primary and auxiliary loads. [Background technology]

[0003] Energy systems with multiple energy sources and sinks are common in many industries. One example is the automotive industry. Having evolved over the past century, today's automotive technology is characterized by the interplay of motors, mechanical elements, and electronics. These are key components that influence vehicle performance and the driver's experience. Motors can be combustion-based or electric, and in most cases, rotational energy from the motor is delivered through a suite of highly sophisticated mechanical elements, including clutches, transmissions, differentials, driveshafts, torque tubes, and couplers. These components largely control torque conversion and power distribution to the wheels, determining the vehicle's performance and handling during driving.

[0004] Electric vehicles (EVs) contain various electrical systems associated with the drivetrain, such as a battery pack, charger, and motor control. A high-voltage battery pack typically consists of low-voltage battery modules connected in series. Each such module further contains a group of individual cells connected in series and a simple, embedded battery management system (BMS) for regulating basic cell-related characteristics such as state of charge and voltage. No electronics with more advanced capabilities or any form of smart interconnectivity is present. As a result, monitoring or control functions are operated by individual systems, which, even if present elsewhere in the vehicle, lack the ability to monitor individual cell health, state of charge, temperature, or other performance-affecting metrics. They also lack the ability to meaningfully regulate individual cell power consumption in any way. Some of the key consequences are: (1) the weakest cell limits the performance of the entire battery pack; (2) failure of any cell or module may require replacement of the entire battery pack and / or prevent operation of the EV until the cell or module is repaired or replaced; (3) battery reliability and safety are significantly reduced; and (4) battery life is limited. (5) Thermal management is difficult, (6) the battery pack always operates below its maximum capacity, and (7) the sudden influx of power from regenerative braking cannot be easily stored in the battery and must be dissipated through a damping resistor.

[0005] Charging circuits in EVs are typically implemented as separate on-board systems. They accept power from outside the EV in the form of AC or DC signals, process it, and convert it to DC for delivery to the battery pack. The charging system monitors voltage and current and typically provides a steady, constant supply. Given the design of the battery pack and typical charging circuits, there is little ability to adjust charge flow to individual battery modules based on cell health, performance characteristics, temperature, etc. Charging cycles are also typically long, as the charging system and battery pack lack circuitry that enables pulse charging or other techniques that optimize achievable charge transfer and total charge.

[0006] Traditional control includes a DC-DC converter to adjust the battery pack's voltage level to match the EV's electrical system bus voltage. The motor is then driven by a simple two-level multi-phase converter, which provides the electric motor with the necessary AC signal. Traditionally, each motor is controlled by a separate controller, driving the motors in a three-phase design. For a dual-motor EV, two controllers are required, and for an EV with four motors, four individual controllers are required. Traditional controller designs also lack the ability to drive next-generation motors, such as switched reluctance motors (SRMs), which feature more pole pieces. To accommodate, more multi-phase designs are required, making the system more complex and ultimately unable to handle electrical noise and drive performance issues, such as high torque ripple and acoustic noise.

[0007] Many of these deficiencies apply not only to automobiles, but also to other motor-driven vehicles, and to a significant extent, to stationary applications. For these and other reasons, a need exists for improved systems, apparatus, and methods for energy systems for mobile and stationary applications. Summary of the Invention [Means for solving the problem]

[0008] Provided herein are example embodiments of systems, apparatus, and methods for a modular energy system configured to power primary and auxiliary loads. Each module can include an energy source and switch circuitry that selectively couples the energy source to other modules in the system to generate electrical power or to receive and store electrical power from a charging source. The energy system can be configured in single-phase topologies and multi-phase topologies with multiple interconnected arrays.

[0009] The energy system can be configured to provide polyphase power to a primary AC load, such as an EV's motor, and DC power to auxiliary loads, such as the EV's on-board electrical network and the EV's HVAC system. The energy system can include multiple arrays of modules for each phase, and the arrays for each phase can be coupled at a common point. For example, each array can include a phase port and a neutral port, between which an AC voltage signal is generated. The neutral port of each array corresponding to a phase can be coupled, and the phase ports can be coupled to one or more AC loads.

[0010] For one or more three-phase loads, the energy system can include three array segments, one for each phase. Each segment can include two or more arrays configured to generate and output a single-phase AC signal in phase. The arrays within each segment can be coupled at a neutral point. Each three-phase load can be coupled to a phase terminal of an array in each segment to receive three-phase power.

[0011] The energy system may also include a auxiliary signal conversion device (SSCD) configured to power an auxiliary load, for example, an auxiliary DC load. The SSCD may be configured to receive an AC signal from the array of modules, convert the AC signal to a DC signal, and condition the DC signal for the auxiliary load.

[0012] The SSCD may also be configured to balance one or more operating characteristics of the modules of the array, the array itself, and / or groups of arrays. For example, the SSCD may be controlled in various ways to selectively draw power from the array or groups of arrays for use in supplying auxiliary loads in order to balance one or more operating characteristics of the modules, arrays, and / or groups.

[0013] In certain examples, an EV can include one or more primary AC motor loads and one or more auxiliary DC loads. The EV can also include an energy system including a segment of the array for each phase of the AC motor and an SSCD configured to receive power from the segments of the array and generate and supply DC power to the auxiliary loads.

[0014] The array segments can be arranged in modular packs to allow the packs to be easily connected to loads in different configurations. For example, modular packs can be configured to easily connect to the motor of a single-motor EV or both motors of a dual-motor EV with no or minimal modification to the modular pack. This simplifies the manufacturing of the modular pack and the overall energy system, as well as allowing modular packs to be interchangeable between different types of EVs.

[0015] Other systems, devices, methods, features, and advantages of the subject matter described herein will be apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. All such additional systems, methods, features, and advantages are included within this description and are within the scope of the subject matter described herein. Features of the example embodiments should not be construed as limiting the scope of the appended claims unless those features are expressly recited in the claims.

[0016] Details of the subject matter described herein, both as to its structure and operation, will become apparent from examination of the accompanying figures, in which like reference numerals refer to like parts. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the subject matter. Furthermore, all figures are for conceptual purposes only, and relative size, shape, and other detailed attributes may be depicted diagrammatically, rather than literally or accurately. [Brief explanation of the drawings]

[0017] [Figure 1A]FIG. 1 is a block diagram illustrating an example embodiment of a modular energy system. [Figure 1B] FIG. 1 is a block diagram illustrating an example embodiment of a modular energy system. [Figure 1C] FIG. 1 is a block diagram illustrating an example embodiment of a modular energy system. [Figure 1D] 1 is a block diagram illustrating an example embodiment of a control device for an energy system. [Figure 1E] 1 is a block diagram illustrating an example embodiment of a control device for an energy system. [Figure 1F] FIG. 1 is a block diagram illustrating an example embodiment of a modular energy system coupled to a load and a charging source. [Figure 1G] FIG. 1 is a block diagram illustrating an example embodiment of a modular energy system coupled to a load and a charging source. [Figure 2A] FIG. 1 is a block diagram illustrating an example embodiment of a module and control system within an energy system. [Figure 2B] FIG. 1 is a block diagram illustrating an example embodiment of a module and control system within an energy system. [Figure 2C] FIG. 2 is a block diagram illustrating an example embodiment of the physical configuration of a module. [Figure 2D] FIG. 1 is a block diagram illustrating an example embodiment of the physical configuration of a modular energy system. [Figure 3A] 1A-1C are block diagrams illustrating example embodiments of modules having various electrical configurations. [Figure 3B] 1A-1C are block diagrams illustrating example embodiments of modules having various electrical configurations. [Figure 3C] 1A-1C are block diagrams illustrating example embodiments of modules having various electrical configurations. [Figure 4A] FIG. 1 is a schematic diagram illustrating an example embodiment of an energy source. [Figure 4B] FIG. 1 is a schematic diagram illustrating an example embodiment of an energy source. [Figure 4C]FIG. 1 is a schematic diagram illustrating an example embodiment of an energy source. [Figure 4D] FIG. 1 is a schematic diagram illustrating an example embodiment of an energy source. [Figure 4E] FIG. 1 is a schematic diagram illustrating an example embodiment of an energy source. [Figure 4F] FIG. 1 is a schematic diagram illustrating an example embodiment of an energy source. [Figure 5A] FIG. 1 is a schematic diagram illustrating an example embodiment of an energy buffer. [Figure 5B] FIG. 1 is a schematic diagram illustrating an example embodiment of an energy buffer. [Figure 5C] FIG. 1 is a schematic diagram illustrating an example embodiment of an energy buffer. [Figure 6A] FIG. 1 is a schematic diagram illustrating an example embodiment of a converter. [Figure 6B] FIG. 1 is a schematic diagram illustrating an example embodiment of a converter. [Figure 6C] FIG. 1 is a schematic diagram illustrating an example embodiment of a converter. [Figure 7A] 1A-1D are block diagrams illustrating example embodiments of modular energy systems having various topologies. [Figure 7B] 1A-1D are block diagrams illustrating example embodiments of modular energy systems having various topologies. [Figure 7C] 1A-1D are block diagrams illustrating example embodiments of modular energy systems having various topologies. [Figure 7D] 1A-1D are block diagrams illustrating example embodiments of modular energy systems having various topologies. [Figure 7E] 1A-1D are block diagrams illustrating example embodiments of modular energy systems having various topologies. [Figure 8A] FIG. 10 is a plot illustrating an example output voltage of a module. [Figure 8B] FIG. 1 is a plot illustrating an example of a multi-level output voltage of an array of modules. [Figure 8C] FIG. 1 is a plot illustrating an example of a reference signal and a carrier signal that can be used in a pulse width modulation control technique. [Figure 8D] FIG. 1 is a plot illustrating an example of a reference signal and a carrier signal that can be used in a pulse width modulation control technique. [Figure 8E] FIG. 1 is a plot illustrating an example of a switch signal generated according to a pulse width modulation control technique. [Figure 8F] FIG. 1 is a plot illustrating an example of a multi-level output voltage produced by superimposing output voltages from an array of modules under pulse width modulation control techniques. [Figure 9A] FIG. 1 is a block diagram illustrating an example embodiment of a controller for a modular energy system. [Figure 9B] FIG. 1 is a block diagram illustrating an example embodiment of a controller for a modular energy system. [Figure 10] FIG. 1 is a block diagram illustrating an example embodiment of a multi-phase modular energy system having interconnected modules. [Figure 11] FIG. 1 is a block diagram of an example embodiment of a modular energy system having a module pack and an auxiliary signal conversion device. [Figure 12A] FIG. 1 is a block diagram of an example embodiment of a module pack. [Figure 12B] FIG. 1 is a block diagram of an example embodiment of a module pack. [Figure 12C] FIG. 1 is a block diagram of an example embodiment of a module pack. [Figure 12D] FIG. 1 is a block diagram of an example embodiment of a module pack. [Figure 12E] FIG. 1 is a block diagram of an example embodiment of a module pack. [Figure 13A] FIG. 1 is a block diagram of an example embodiment of a modular energy system having a module pack and an SSCD for powering a primary load and an auxiliary load. [Figure 13B] FIG. 1 is a block diagram of an example embodiment of a modular energy system having a module pack and an SSCD for powering a primary load and an auxiliary load. [Figure 13C]FIG. 1 is a block diagram of an example embodiment of a modular energy system having a module pack and an SSCD for powering a primary load and an auxiliary load. [Figure 13D] FIG. 1 is a block diagram of an example embodiment of an SSCD for powering an auxiliary load. [Figure 13E] 1A-1C illustrate example embodiments of connectors for coupling a module pack to an SSCD. [Figure 13F] FIG. 10 is a diagram illustrating an example of an equivalent rectifier circuit when controlling a single motor. [Figure 13G] FIG. 10 is a diagram showing an example of an equivalent module pack configuration when controlling a single motor. [Figure 13H] FIG. 10 is a diagram illustrating an example of a control method for single motor control. [Figure 13I] FIG. 10 is a diagram illustrating an example of an equivalent rectifier circuit when controlling two motors. [Figure 13J] FIG. 10 is a diagram showing an example of an equivalent module pack configuration when controlling two motors. [Figure 13K] FIG. 1 is a diagram illustrating an example of a control method for two-motor control. [Figure 13L] FIG. 10 illustrates an example of an equivalent rectifier circuit during charging in a single motor embodiment. [Figure 13M] FIG. 10 illustrates an example of an equivalent module pack configuration during charging in a single motor embodiment. [Figure 13N] FIG. 10 is a diagram showing an example of an equivalent rectifier circuit during charging in a two-motor embodiment. [Figure 13O] FIG. 10 shows an example of an equivalent module pack configuration during charging in a two motor embodiment. [Figure 14A] FIG. 1 is a block diagram of an example embodiment of a modular energy system having a module pack and an SSCD for powering a primary load and an auxiliary load. [Figure 14B] FIG. 1 is a block diagram of an example embodiment of a modular energy system having a module pack and an SSCD for powering a primary load and an auxiliary load. [Figure 14C]FIG. 1 is a block diagram of an example embodiment of an SSCD for powering an auxiliary load. [Figure 14D] FIG. 10 is a diagram illustrating an example of an equivalent rectifier circuit when controlling a single motor. [Figure 14E] FIG. 10 is a diagram showing an example of an equivalent module pack configuration when controlling a single motor. [Figure 14F] FIG. 10 is a diagram illustrating an example of a control method for single motor control. [Figure 14G] FIG. 10 is a diagram illustrating an example of an equivalent rectifier circuit when controlling two motors. [Figure 14H] FIG. 10 is a diagram showing an example of an equivalent module pack configuration when controlling two motors. [Figure 14I] FIG. 1 is a diagram illustrating an example of a control method for two-motor control. [Figure 14J] 10A-10C show examples of equivalent rectifier circuits during charging for single-motor and dual-motor embodiments. [Figure 14K] 10A-10C show examples of equivalent module pack configurations during charging for single motor and two motor embodiments. [Figure 15A] FIG. 1 is a block diagram of an example embodiment of a modular energy system having a module pack and an SSCD for powering a primary load and an auxiliary load. [Figure 15B] FIG. 1 is a block diagram of an example embodiment of a modular energy system having a module pack and an SSCD for powering a primary load and an auxiliary load. [Figure 15C] FIG. 1 is a block diagram of an example embodiment of an SSCD for powering an auxiliary load. [Figure 15D] FIG. 10 is a diagram illustrating an example of an equivalent rectifier circuit when controlling a single motor. [Figure 15E] FIG. 10 is a diagram showing an example of an equivalent module pack configuration when controlling a single motor. [Figure 15F] FIG. 10 is a diagram illustrating an example of a control method for single motor control. [Figure 15G] FIG. 10 is a diagram illustrating an example of an equivalent rectifier circuit when controlling two motors. [Figure 15H] FIG. 10 is a diagram showing an example of an equivalent module pack configuration when controlling two motors. [Figure 15I] FIG. 1 is a diagram illustrating an example of a control method for two-motor control. [Figure 15J] 10A-10C show examples of equivalent rectifier circuits during charging for single-motor and dual-motor embodiments. [Figure 15K] 10A-10C show examples of equivalent module pack configurations during charging for single motor and two motor embodiments. [Figure 16] FIG. 1 is a flow diagram illustrating an example embodiment of a method for powering a primary load and an auxiliary load. DETAILED DESCRIPTION OF THE INVENTION

[0018] Before describing the present subject matter in more detail, it is to be understood that the present subject matter is not limited to particular embodiments described, which may, of course, vary. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting, since the scope of the present disclosure will be limited only by the appended claims.

[0019] Before describing example embodiments related to modular energy systems that power primary and auxiliary loads, it is useful to first describe these underlying systems in more detail. The following sections, with reference to Figures 1A-10F, describe various applications in which embodiments of modular energy systems, embodiments of control systems or apparatus for modular energy systems, configurations of embodiments of modular energy systems with respect to charging sources and loads, embodiments of individual modules, embodiments of topologies for placement of modules within a system, embodiments of control methodologies, embodiments for balancing operational characteristics of modules within a system, and embodiments for use of interconnected modules may be implemented.

[0020] Examples of uses Stationary applications are those in which a modular energy system is installed at a fixed location during use but may be movable to another location when not in use. The modular energy system is installed at a static location and supplies electrical energy for consumption by one or more other entities or stores or buffers energy for later consumption. Examples of stationary applications in which embodiments disclosed herein may be used include, but are not limited to, energy systems used by or within one or more residential structures or areas, energy systems used by or within one or more industrial structures or areas, energy systems used by or within one or more commercial structures or areas, energy systems used by or within one or more government structures or areas (including both military and non-military applications), energy systems (e.g., charging sources or charging stations) for charging mobile applications described below, and systems that convert and store solar, wind, geothermal, fossil fuel, or nuclear energy. Stationary applications often supply loads such as power grids and microgrids, motors, and data centers. Stationary energy systems can be used in both storage and non-storage roles.

[0021] Mobile applications (sometimes referred to as traction applications) generally involve applications in which a modular energy system is installed on or within an entity to store and provide electrical energy that is converted by a motor into propulsion to move or assist the movement of the entity. Examples of mobile entities in which the embodiments disclosed herein may be used include, but are not limited to, electric and / or hybrid entities that travel on or under land, on or under the sea, above land or sea but not in contact with land or sea (e.g., flying or hovering in the air), or in space. Examples of mobile entities in which the embodiments disclosed herein may be used include, but are not limited to, cars, trains, trams, ships, watercraft, aircraft, and spacecraft. Examples of mobile vehicles in which the embodiments disclosed herein may be used include, but are not limited to, those with only one wheel or track, those with only two wheels or tracks, those with only three wheels or tracks, those with only four wheels or tracks, and those with five or more wheels or tracks. Examples of mobile vehicles in which the embodiments disclosed herein may be used include, but are not limited to, automobiles, buses, trucks, motorcycles, scooters, bicycles, industrial vehicles, mining vehicles, air vehicles (e.g., airplanes, helicopters, drones, etc.), marine vessels (e.g., commercial ships, ships, yachts, boats, or other watercraft), submarines, locomotives or rail vehicles (e.g., trains, trams, etc.), military vehicles, spacecraft, and satellites.

[0022] In describing embodiments herein, reference may be made to a particular stationary application (e.g., a power grid, a micro-power grid, a data center, a cloud computing environment, etc.) or a mobile application (e.g., an electric vehicle, etc.). Such references are made for ease of description and do not imply that a particular embodiment is limited to use only in that particular mobile or stationary application. Embodiments of a system for providing power to a motor can be used in both mobile and stationary applications. While certain configurations may be better suited for some applications than others, all example embodiments disclosed herein can be used in both mobile and stationary applications unless otherwise specified.

[0023] Example of a modular energy system FIG. 1A is a block diagram illustrating an example embodiment of a modular energy system 100. Here, system 100 includes a control system 102 communicatively coupled to N converter-source modules 108-1 through 108-N via communication paths or links 106-1 through 106-N, respectively. The modules 108 are configured to store energy and output that energy to a load 101 (or other modules 108) as needed. In these embodiments, any number of two or more modules 108 may be used (e.g., N is 2 or greater). The modules 108 may be connected to each other in various ways, as described in more detail with respect to FIGS. 7A-7E. For ease of illustration, FIGS. 1A-1C show the modules 108 connected in series or as a one-dimensional array, with the Nth module coupled to the load 101.

[0024] System 100 is configured to provide power to load 101. Load 101 can be any type of load, such as a motor or a power grid. System 100 is also configured to store power received from a charging source. FIG. 1F is a block diagram illustrating an example embodiment of system 100 with a power input interface 151 for receiving power from charging source 150 and a power output interface for outputting power to load 101. In this embodiment, system 100 can output power via interface 152 while simultaneously receiving and storing power via interface 151. FIG. 1G is a block diagram illustrating another example embodiment of system 100 with a switchable interface 154. In this embodiment, system 100 can select, or be instructed to select, between receiving power from charging source 150 and outputting power to load 101. System 100 may be configured to supply power to multiple loads 101, including both primary and auxiliary loads, and / or may be configured to receive power from multiple charging sources 150 (e.g., a power grid operated by a utility company and local renewable energy sources (e.g., solar power). Charging source 150 may be an AC charging source that provides an AC charging signal or a DC charging source that provides a DC charging signal. For example, if system 100 is part of an EV, charging source 150 may be an AC charging station or a DC charging station, e.g., a DC fast charging station.

[0025] 1B illustrates another example embodiment of system 100, where control system 102 is implemented as a master controller (MCD) 112 communicatively coupled to N different local controllers (LCDs) 114-1 through 114-N via communication paths or links 115-1 through 115-N, respectively. Each LCD 114-1 through 114-N is communicatively coupled to one module 108-1 through 108-N via communication paths or links 116-1 through 116-N, respectively, such that there is a 1:1 relationship between the LCDs 114 and the modules 108.

[0026] 1C illustrates another example embodiment of system 100, in which MCD 112 is communicatively coupled to M different LCDs 114-1 through 114-M via communication paths or links 115-1 through 115-M, respectively. Each LCD 114 is coupled to and can control two or more modules 108. In the illustrated example, each LCD 114 is communicatively coupled to two modules 108, and M LCDs 114-1 through 114-M are coupled to 2M modules 108-1 through 108-2M via communication paths or links 116-1 through 116-2M, respectively.

[0027] The control system 102 may be configured as a single device for the entire system 100 (e.g., FIG. 1A), or may be distributed among or implemented as multiple devices (e.g., FIGS. 1B, 1C). In some embodiments, the control system 102 may be distributed among the LCDs 114 associated with the modules 108, and the MCD 112 may not be required and may be omitted from the system 100.

[0028] Control system 102 can be configured to perform control using software (instructions stored in memory executable by processing circuitry), hardware, or a combination thereof. One or more devices of control system 102 can each include processing circuitry 120 and memory 122, as shown. Example implementations of processing circuitry and memory are further described below.

[0029] The control system 102 may have a communication interface for communicating with devices 104 external to the system 100 via communication links or paths 105. For example, the control system 102 (e.g., the MCD 112) may output data or information related to the system 100 to another control device 104 (e.g., a vehicle electronic control unit (ECU) or motor control unit (MCU) in a mobile application, a grid controller in a stationary application, etc.).

[0030] Communication paths or links 105, 106, 115, 116, and the communication paths or links described below (e.g., communication path or link 118 in FIG. 2B , 1131, 1132, 1133, and 1135 in FIG. 11 , 1391 and 1392 in FIG. 13H , and 1394-1397 in FIG. 13K ), can each be a wired (e.g., electrical, optical) or wireless communication path that communicates data or information bidirectionally in parallel or serially. Data can be communicated in a standardized format (e.g., IEEE, ANSI) or a custom format (e.g., proprietary). In automotive applications, communication path 115 can be configured to communicate according to the FlexRay or CAN protocol. Communication paths 106, 115, 116, and 118 can also carry wired power to directly provide operating power for system 102 from one or more modules 108. For example, the operating power of each LCD 114 may be supplied solely by the one or more modules 108 to which that LCD 114 is connected, and the operating power of the MCD 112 may be supplied indirectly from one or more of the modules 108 (e.g., via the vehicle's power network, etc.).

[0031] The control system 102 is configured to control one or more modules 108 based on status information received from the same or different one or more of the modules 108, and may also control based on one or more other factors, such as the requirements of the load 101. Controllable items include, but are not limited to, one or more of the voltage, current, phase, and / or output power of each module 108.

[0032] Status information for each module 108 in the system 100 can be communicated to the control system 102, which can control each module 108-1...108-N independently. Other variations are possible. For example, a particular module 108 (or a subset of modules 108) can be controlled based on status information for that particular module 108 (or subset), based on status information for a different module 108 that is not the particular module 108 (or subset), based on status information for all modules 108 other than the particular module 108 (or subset), based on status information for the particular module 108 (or subset) and status information for at least one other module 108 that is not the particular module 108 (or subset), or based on status information for all modules 108 in the system 100.

[0033] The status information may be information about one or more items, characteristics, or parameters of each module 108. Types of status information may include, but are not limited to, the following items of a module 108 or one or more components thereof (e.g., energy source, energy buffer, converter, monitoring circuit): State of Charge (SOC) of one or more energy sources of the module (e.g., the charge level of an energy source relative to its capacity, such as a fraction or a percentage), State of Health (SOH) of one or more energy sources of the module (e.g., a performance indicator of the condition of an energy source compared to ideal conditions), temperature of one or more energy sources or other components of the module, capacity of one or more energy sources of the module, voltage of one or more energy sources and / or other components of the module, current of one or more energy sources and / or other components of the module, State of Power (SOP) (e.g., a limit on the available power of an energy source during discharging and / or charging), State of Energy (SOE) (e.g., the current level of available energy of an energy source relative to the maximum available energy of the energy source), and / or the presence or absence of a fault in any one or more of the module's components. These aspects of the module 108 may also be referred to as the operating characteristics of the module 108 .

[0034] The LCD 114 can be configured to receive status information from each module 108 or determine status information from monitoring signals or data received from or within each module 108 and communicate that information to the MCD 112. In some embodiments, each LCD 114 can communicate collected raw data to the MCD 112, which then algorithmically determines status information based on the raw data. The MCD 112 can use the status information of the modules 108 to make control decisions accordingly. The decisions may take the form of instructions, commands, or other information (such as a modulation index, as described herein) that can be utilized by the LCD 114 to maintain or adjust the operation of each module 108.

[0035] For example, the MCD 112 may receive status information and evaluate the information to determine differences between at least one module 108 (e.g., its components) and at least one or more other modules 108 (e.g., its comparable components). For example, the MCD 112 may determine that a particular module 108 is operating in one of the following conditions compared to one or more other modules 108: a relatively low or high SOC, a relatively low or high SOH, a relatively low or high capacity, a relatively low or high voltage, a relatively low or high current, a relatively low or high temperature, or the presence or absence of a fault. In such an example, the MCD 112 may output module control information to reduce or increase (as the condition requires) a relevant aspect (e.g., output voltage, current, power, temperature) of the particular module 108. In this manner, the utilization of the outlier module 108 (e.g., operating at a relatively low SOC or high temperature) can be reduced, and the relevant parameter (e.g., SOC or temperature) of that module 108 can be brought closer to the parameters of one or more other modules 108.

[0036] The determination of whether to adjust the operation of a particular module 108 can be made by comparing the status information to predetermined thresholds, limits, or conditions, not necessarily the status of other modules 108. The predetermined thresholds, limits, or conditions can be static thresholds, limits, or conditions that do not change during use, such as those set by the manufacturer. The predetermined thresholds, limits, or conditions can be dynamic thresholds, limits, or conditions that are allowed to or change during use. For example, the MCD 112 can adjust the operation of a module 108 if the status information for that module 108 indicates that the module 108 is operating in violation of (e.g., above or below) a predetermined threshold or limit, or outside of predetermined acceptable operating conditions. Similarly, the MCD 112 can adjust the operation of a module 108 if the status information for that module 108 indicates the presence of an actual or potential fault (e.g., an alarm, a warning), or the absence or removal of an actual or potential fault. Examples of faults include, but are not limited to, actual component failure, potential component failure, short circuit or other excessive current condition, open circuit, excessive voltage condition, failure to receive communication, reception of corrupted data, etc. Depending on the type and severity of the fault, the utilization of the faulty module may be reduced to avoid damage to the module, or utilization of the module may be completely disabled. For example, if a particular module fails, the MCD 112 or LCD 114 may place that module in a bypass state as described herein.

[0037] The MCD 112 can control the modules 108 in the system 100 to achieve or approach a desired goal. The goal, for example, is for all modules 108 to operate at the same or similar levels relative to one another or within predetermined thresholds, limits, or conditions. This process is also referred to as balancing, i.e., seeking to balance the operations or operating characteristics of the modules 108. The term "balance" as used herein does not require absolute equality between the modules 108 or their components, but rather can be used in a broader sense to convey that the operation of the system 100 can be used to actively reduce disparities in operation (or operating states) between the modules 108 that would otherwise exist.

[0038] The MCD 112 can communicate module control information to the LCD 114 for the purpose of controlling the module 108 associated with the LCD 114. The control information can be, for example, a modulation index and reference signal as described herein, a modulated reference signal, or others. Each LCD 114 can use (e.g., receive and process) the module control information to generate switch signals that control the operation of one or more components (e.g., converters) in the associated module(s) 108. In some embodiments, the MCD 112 generates and outputs switch signals directly to the LCD 114, which then relays the switch signals to the intended module components.

[0039] All or a portion of the control system 102 can be combined with a system external controller 104 that controls one or more other items in a mobile or stationary application. When integrated into this shared or common controller (or subsystem), control of the system 100 can be implemented in any desired manner, such as by one or more software applications executed by processing circuitry of the shared device, by hardware of the shared device, or a combination thereof. Non-exhaustive examples of external controllers 104 include: a vehicle ECU or MCU capable of controlling one or more other vehicle functions (e.g., motor control, driver interface control, traction control, etc.); a grid or microgrid controller responsible for one or more other power management functions, such as load interfacing, load power demand forecasting, power transmission and switching, interfacing with charging sources (e.g., diesel, solar, wind), charging source power forecasting, backup power monitoring, and facility operational control; and a data center control subsystem (e.g., environmental control, network control, backup control, etc.).

[0040] 1D and 1E are block diagrams illustrating an example embodiment of a shared or common controller (or system) 132 in which control system 102 may be implemented. In FIG. 1D , common controller 132 includes master controller 112 and external controller 104. Master controller 112 includes interface 141 for communicating with LCD 114 via path 115 and interface 142 for communicating with external controller 104 via internal communication bus 136. External controller 104 includes interface 143 for communicating with master controller 112 via bus 136 and interface 144 for communicating with other entities throughout the application (e.g., vehicle or grid components) via communication path 136. In some embodiments, common controller 132 may be integrated into a common housing or package with devices 112 and 104, which are housed therein as individual integrated circuit (IC) chips or packages.

[0041] In FIG. 1E, external controller 104 functions as common controller 132, with primary control functions implemented as components within device 104. This component 112 can be or include software or other program instructions stored and / or hard-coded within device 104's memory and executed by its processing circuitry. Components can also include dedicated hardware. Components can be self-contained modules or cores with one or more internal hardware and / or software interfaces (e.g., application program interfaces (APIs)) for communicating with external controller 104's operating software. External controller 104 can manage communications with LCD 114 via interface 141 and with other devices via interface 144. In various embodiments, devices 104 / 132 can be integrated as a single IC chip, multiple IC chips in a single package, or multiple semiconductor packages in a common housing.

[0042] 1D and 1E, the main control functionality of the system 102 is shared by the common device 132, although other divisions of the shared control are permissible. For example, some of the main control functionality may be distributed between the common device 132 and the dedicated MCD 112. In another example, both the main control functionality and at least some of the local control functionality may be implemented in the common device 132 (e.g., with the remaining local control functionality implemented in the LCD 114). In some embodiments, all of the control system 102 is implemented in the common device (or subsystem) 132. In some embodiments, the local control functionality is implemented in a device shared with another component of each module 108, such as a battery management system (BMS).

[0043] Example of a module in a cascade energy system The module 108 can include one or more energy sources and a power electronics converter, and, if desired, an energy buffer. FIGS. 2A-2B are block diagrams illustrating additional example embodiments of the system 100 including a module 108 having a power converter 202, an energy buffer 204, and an energy source 206. The converter 202 can be a voltage converter or a current converter. While embodiments are described herein with reference to a voltage converter, the embodiments are not limited thereto. The converter 202 can be configured to convert a direct current (DC) signal from the energy source 206 to an alternating current (AC) signal and output it via the power connection 110 (e.g., an inverter). The converter 202 can also receive an AC or DC signal via the connection 110 and apply it to the energy source 206 in either continuous or pulsed polarity. The converter 202 can be or include a configuration of switches (e.g., power transistors), such as a half-bridge or full-bridge (H-bridge). In some embodiments, the converter 202 includes only switches, and the converter (and the module as a whole) does not include a transformer.

[0044] Converter 202 may also (or alternatively) be configured to perform AC-to-DC conversion (e.g., as a rectifier), DC-to-DC conversion, and / or AC-to-AC conversion (e.g., in combination with an AC-DC converter), such as for charging a DC energy source from an AC power source. In some embodiments that perform AC-to-AC conversion, converter 202 may include a transformer, alone or in combination with one or more power semiconductors (e.g., switches, diodes, thyristors, etc.). In other embodiments where weight and cost are important factors, converter 202 may be configured to perform the conversion with only power switches, power diodes, or other semiconductor devices, without a transformer.

[0045] Energy source 206 is preferably a robust energy storage device capable of outputting direct current and having an energy density suitable for energy storage applications for electrically powered devices. Energy source 206 can be an electrochemical battery, such as a single battery cell, or multiple battery cells connected in a battery module or array, or any combination thereof. Figures 4A-4D are schematic diagrams illustrating example embodiments of energy source 206 configured as a single battery cell 402 (Figure 4A), a battery module having a series connection of multiple (e.g., four) cells 402 (Figure 4B), a battery module having a parallel connection of a single cell 402 (Figure 4C), and a battery module having a parallel connection of legs each having two cells 402 (Figure 4D). A non-exhaustive list of example battery types is provided elsewhere herein.

[0046] Energy source 206 can also be a high-energy density (HED) capacitor, such as an ultracapacitor or supercapacitor. HED capacitors differ from typical solid-dielectric electrolytic capacitors in that they can be double-layer capacitors (electrostatic charge storage), pseudocapacitors (electrochemical charge storage), hybrid capacitors (electrostatic and electrochemical), or other configurations. In addition to high capacitance, HED capacitors can have energy densities 10 to 100 times (or more) that of electrolytic capacitors. For example, HED capacitors can have specific energies greater than 1.0 watt-hours per kilogram (Wh / kg) and capacitances greater than 10-100 Farads (F). Similar to the battery described with respect to FIGS. 4A-4D, energy source 206 can be configured as a single HED capacitor or as multiple HED capacitors connected in an array (e.g., in series, parallel, or a combination thereof).

[0047] The energy source 206 can also be a fuel cell. The fuel cell can be a single fuel cell, multiple fuel cells connected in series or parallel, or a fuel cell module. Types of fuel cells include proton exchange membrane fuel cells (PEMFCs), phosphoric acid fuel cells (PAFCs), solid acid fuel cells, alkaline fuel cells, high temperature fuel cells, solid oxide fuel cells, and molten electrolyte fuel cells. Similar to the batteries described with respect to FIGS. 4A-4D , the energy source 206 can be configured as a single fuel cell or multiple fuel cells connected in an array (e.g., in series, parallel, or a combination thereof). The foregoing examples of source classes (e.g., batteries, capacitors, and fuel cells) and types (e.g., chemistry and / or structural configurations within each class) are not intended to form an exhaustive list, and one of ordinary skill in the art will recognize other variations within the scope of the present subject matter.

[0048] The energy buffer 204 is connected to a DC line or link (e.g., +V DCL and -V DCL ) can suppress or filter fluctuations in the current across the source 206, helping to maintain a stable DC link voltage. These fluctuations can be relatively low (e.g., kilohertz) or high (e.g., megahertz) frequency fluctuations or harmonics caused by the switching of the converter 202 or other transients. These fluctuations can be absorbed by the buffer 204 instead of being sent to the source 206 or ports IO3 and IO4 of the converter 202.

[0049] The power connection 110 is a connection for transferring energy or power to, from, and through the module 108. The module 108 can output energy from an energy source 206 to the power connection 110, where the energy can be transferred to other modules or loads in the system. The module 108 can also receive energy from other modules 108 or from charging sources (DC chargers, single-phase chargers, multi-phase chargers). Signals can also bypass the energy source 206 and pass through the module 108. The routing of energy or power to the module 108 is performed by the converter 202 under the control of the LCD 114 (or another entity in the system 102).

[0050] In the embodiment of Figure 2A, the LCD 114 is implemented as a component separate from the module 108 (e.g., not in a shared module housing) and is connected to and can communicate with the converter 202 via communication path 116. In the embodiment of Figure 2B, the LCD 114 is included as a component of the module 108 and is connected to and can communicate with the converter 202 via an internal communication path 118 (e.g., a shared bus or individual connections). The LCD 114 can also receive signals from and send signals to the energy buffer 204 and / or the energy source 206 via paths 116 or 118.

[0051] The module 108 may also include monitoring circuitry 208 configured to monitor (e.g., collect, sense, measure, and / or determine) one or more items of the module 108 and / or its components, such as voltage, current, temperature, or other operating parameters that constitute status information (or that may be used to determine status information, e.g., by the LCD 114). The primary function of the status information is to describe the state of one or more energy sources 206 of the module 108 so that a determination can be made as to how much of that energy source to utilize relative to other energy sources in the system 100; however, status information describing the state of other components (e.g., voltage, temperature, and / or the presence of a fault in the buffer 204, the presence of a fault in the temperature and / or converter 202, the presence of a fault elsewhere in the module 108, etc.) may be used in the utilization determination as well. The monitoring circuitry 208 may include one or more sensors, shunts, dividers, fault detectors, coulomb counters, controllers, or other hardware and / or software configured to monitor such items. The monitoring circuitry 208 may be separate from the various components 202, 204, and 206, or may be integrated with each component 202, 204, and 206 (as shown in FIGS. 2A-2B), or any combination thereof. In some embodiments, the monitoring circuitry 208 may be part of or shared with a battery management system (BMS) for the battery energy source 204. Individual circuits for monitoring each type of status information are not required, as multiple types of status information can be monitored by a single circuit or device or determined by an algorithm without the need for additional circuitry.

[0052] The LCD 114 can receive status information (or raw data) regarding the module components via communication paths 116, 118. The LCD 114 can also transmit information to the module components via paths 116, 118. Paths 116 and 118 can include diagnostic, measurement, protection, and control signal lines. The transmitted information can be control signals for one or more module components. The control signals can be switch signals for the transducer 202 and / or one or more signals requesting status information from the module components. For example, the LCD 114 can cause the status information to be transmitted via paths 116, 118 by directly requesting the status information or, in some cases, by applying a stimulus (e.g., a voltage) to generate the status information in combination with a switch signal that places the transducer 202 in a particular state.

[0053] The physical configuration and layout of the module 108 can take a variety of forms. In some embodiments, the module 108 can include a common housing in which all module components, such as the converter 202, buffer 204, and source 206, are housed, along with other optional components, such as an integrated LCD 114. In other embodiments, these components can be housed in separate housings that are secured together. FIG. 2C illustrates a block diagram of an example embodiment of the module 108, including a first housing 220 that houses the module's energy source 206 and associated electronics, such as monitoring circuitry; a second housing 222 that houses the module electronics, such as the converter 202, energy buffer 204, and monitoring circuitry; and a third housing 224 that houses the LCD 114 (not shown) for the module 108. In an alternative embodiment, the module electronics and the LCD 114 can be housed within the same single housing. In yet other embodiments, the module electronics, LCD 114, and energy source(s) may be housed within the same single housing for module 108. Electrical connections between the various module components may be made through housings 220, 222, 224, or may be exposed on any of the housing exteriors for connection with other devices, such as other modules 108 or MCD 112.

[0054] The modules 108 of the system 100 can be physically arranged relative to each other in various configurations depending on the application needs and the number of loads. For example, in a stationary application where the system 100 supplies power to a microgrid, the modules 108 can be arranged in one or more racks or other frame structures. Such a configuration may also be suitable for larger mobile applications, such as offshore vessels. Alternatively, the modules 108 can be fixed and installed within a common enclosure called a pack. The rack or pack may have a dedicated cooling system shared across all modules. A pack configuration is useful for smaller mobile applications, such as electric vehicles. The system 100 can be implemented with one or more racks (e.g., for parallel supply to a microgrid), one or more packs (e.g., for different motors in a vehicle), or a combination thereof. FIG. 2D is a block diagram illustrating an example embodiment of the system 100 configured as a pack, with nine modules 108 electrically and physically coupled within a common enclosure 230.

[0055] These and other configurations are described in International Application No. PCT / US20 / 25366, filed March 27, 2020, entitled "Module-Based Energy Systems Capable of Cascaded and Interconnected Configurations, and Methods Related Thereto," which is incorporated by reference in its entirety for all purposes.

[0056] 3A-3C are block diagrams illustrating example embodiments of modules 108 having various electrical configurations. These embodiments are described as having one LCD 114 per module 108 housed within the associated module, although other configurations are possible as described herein. FIG. 3A illustrates a first example configuration of a module 108A within system 100. Module 108A includes an energy source 206, an energy buffer 204, and a converter 202A. Each component has a power connection port (terminal, connector, etc.) through which power can be input and / or output, referred to herein as an IO port. Such ports may also be referred to as input ports or output ports depending on the context.

[0057] The energy source 206 may be configured as any of the energy source types described herein (e.g., a battery, HED capacitor, fuel cell, or others, as described with respect to FIGS. 4A-4D ). Ports IO1 and IO2 of the energy source 206 may be connected to ports IO1 and IO2, respectively, of the energy buffer 204. The energy buffer 204 may be configured to buffer or filter high- and low-frequency energy pulsations reaching the buffer 204 via the converter 202 that may otherwise degrade the performance of the module 108. The topology and components of the buffer 204 are selected to accommodate the maximum allowable amplitude of these high-frequency voltage pulsations. Several (non-exhaustive) example embodiments of the energy buffer 204 are shown in the schematic diagrams of FIGS. 5A-5C . In FIG. 5A , the buffer 204 includes an electrolytic and / or film capacitor C EB 5B, the buffer 204 is connected to two inductors L EB1 and L EB2 and two electrolytic and / or film capacitors C EB1 and C EB2 5C, the buffer 204 is formed by two inductors L EB1 and LEB2 and two electrolytic and / or film capacitors C EB1 and C EB2 and diode D EB and a pseudo Z-source network 720 formed by

[0058] Ports IO3 and IO4 of energy buffer 204 can be connected to ports IO1 and IO2, respectively, of converter 202A, which can be configured as any of the power converter types described herein. FIG. 6A is a schematic diagram illustrating an example embodiment of converter 202A configured as a DC-to-AC converter that can receive DC voltages at ports IO1 and IO2 and switch to generate pulses at ports IO3 and IO4. Converter 202A can include multiple switches, here converter 202A includes four switches S3, S4, S5, and S6 arranged in a full-bridge configuration. Control system 102 or LCD 114 can independently control each switch via control input line 118-3 to each gate.

[0059] The switches can be any suitable switch type, such as power semiconductors, such as metal-oxide-semiconductor field-effect transistors (MOSFETs) shown here, insulated-gate bipolar transistors (IGBTs), gallium nitride (GaN) transistors, etc. The semiconductor switches can operate at relatively high switching frequencies, allowing the converter 202 to operate in pulse-width modulation (PWM) mode if desired and respond to control commands in relatively short time intervals. This allows for high tolerance to output voltage regulation and fast dynamic behavior in transient mode.

[0060] In this embodiment, the converter 202 between ports IO1 and IO2 is connected to a DC line voltage V DCL V can be applied to ports IO3 and IO4 by different combinations of switches S3, S4, S5, and S6. DCL By connecting the converter 202 to ports IO3 and IO4, the converter 202 can provide three different voltage outputs (+V DCL, 0, and -V DCL ) can be generated. The switch signal supplied to each switch controls whether the switch is on (closed) or off (open). DCL To obtain -V, switches S3 and S6 are turned on and switches S4 and S5 are turned off. On the other hand, by turning on switches S4 and S5 and turning off switches S3 and S6, -V DCL can be obtained. By turning S4 and S6 off and turning S3 and S5 on, or by turning S3 and S5 off and turning S4 and S6 on, the output voltages can be set to zero (including near zero) or to a reference voltage. These voltages can be output from the module 108 via the power connection 110. Ports IO3 and IO4 of the converter 202 can be connected to (or form) module IO ports 1 and 2 of the power connection 110 to generate output voltages for use with output voltages from other modules 108.

[0061] Control or switch signals for the embodiments of converter 202 described herein can be generated in different ways depending on the control technique utilized by system 100 to generate the output voltage of converter 202. In some embodiments, the control technique is a PWM technique, such as space vector pulse width modulation (SVPWM) or sinusoidal pulse width modulation (SPWM), or variations thereof. FIG. 8A is a voltage versus time graph illustrating an example output voltage waveform 802 of converter 202. For ease of explanation, embodiments herein are described in the context of PWM control techniques, but the embodiments are not limited thereto. Other classes of techniques can also be used. One alternative class is based on hysteresis, examples of which are described in International Publication Nos. WO 2018 / 231810 A1, WO 2018 / 232403 A1, and WO 2019 / 183553 A1, which are incorporated herein by reference for all purposes.

[0062] Each module 108 can be configured with multiple energy sources 206 (e.g., two, three, four, or more). Each energy source 206 of a module 108 can be controllable (switchable) to supply power to (or receive power from) the connection 110 independently of the other energy sources 206 of the module. For example, all sources 206 can simultaneously output power to (or be charged with) the connection 110, or only one (or a subset) of the sources 206 can supply power to (or be charged with) the connection 110 at any one time. In some embodiments, the sources 206 of a module can exchange energy between themselves; for example, one source 206 can charge another source 206. Each energy source 206 can be configured as any energy source described herein (e.g., a battery, an HED capacitor, a fuel cell). Each of the sources 206 can be of the same class (e.g., each can be a battery, each can be an HED capacitor, or each can be a fuel cell). Alternatively, each of the sources 206 can be of a different class (e.g., the first source can be a battery and the second source can be an HED capacitor or a fuel cell, or the first source can be an HED capacitor and the second source can be a fuel cell).

[0063] 3B is a block diagram illustrating an example embodiment of a module 108B in a dual energy source configuration with a primary energy source 206A and a secondary energy source 206B. Ports IO1 and IO2 of the primary source 206A can be connected to ports IO1 and IO2 of the energy buffer 204. Module 108B includes a converter 202B with an additional IO port. Ports IO3 and IO4 of the buffer 204 can be connected to ports IO1 and IO2, respectively, of the converter 202B. Ports IO1 and IO2 of the secondary source 206B can be connected to ports IO5 and IO2, respectively, of the converter 202B (and can also be connected to port IO4 of the buffer 204).

[0064] In this example embodiment of module 108B, primary energy source 202A, along with the other modules 108 in system 100, supplies the average power required by the load. Secondary energy source 206B can function to supplement energy source 202A by providing additional power during peak load power periods, absorbing excess power, or otherwise.

[0065] As previously mentioned, both the primary energy source 206A and the secondary energy source 206B can be utilized simultaneously or at different times depending on the switching state of the converter 202B. When the primary energy source 206A and the secondary energy source 206B are utilized simultaneously, electrolytic capacitors and / or film capacitors (C ES ) can be placed in parallel with energy source 206B to act as an energy buffer for energy source 206B, as shown in Figure 4E. Alternatively, energy source 206B can be configured to utilize a HED capacitor in parallel with another energy source (e.g., a battery or fuel cell), as shown in Figure 4F.

[0066] 6B and 6C are schematic diagrams illustrating example embodiments of converters 202B and 202C, respectively. Converter 202B includes switch circuit portions 601 and 602A. Portion 601 includes switches S3-S6 configured as a full bridge, similar to converter 202A, and configured to selectively couple IO1 and IO2 to either IO3 or IO4, thereby varying the output voltage of module 108B. Portion 602A includes switches S1 and S2 configured as a half bridge and coupled between ports IO1 and IO2. A coupled inductor L C is connected between port IO5 and node 1, which exists between switches S1 and S2, and switch portion 602A is a bidirectional converter that can regulate (boost or buck) voltage (or inversely regulate current). Switch portion 602A connects +V DCL2 and 0. This port IO2 can be at virtual zero potential. The current drawn from or input to the energy source 202B can be controlled by the coupled inductor L, for example, using a pulse width modulation technique or a hysteresis control method to commutate the switches S1 and S2. C This can be controlled by adjusting the voltage at the power supply. Other techniques can also be used.

[0067] Converter 202C differs from converter 202B because switch portion 602B includes switches S1 and S2 configured as a half-bridge and coupled between ports IO5 and IO2. C is connected between port IO1 and node 1, and switch portion 602B is between switches S1 and S2 to regulate the voltage.

[0068] The control system 102 or the LCD 114 can independently control each switch of the converters 202B and 202C via the control input line 118-3 to each gate. In these embodiments and the embodiment of FIG. 6A , the LCD 114 (rather than the MCD 112) generates the switching signals for the converter switches. Alternatively, the MCD 112 can generate the switching signals and communicate them directly to the switches or relay them through the LCD 114. In some embodiments, driver circuitry for generating the switching signals can reside in or be associated with the MCD 112 and / or the LCD 114.

[0069] The aforementioned zero-voltage configuration of converter 202 (S3 and S5 on with S4 and S6 off, or S4 and S6 on with S3 and S5 off) can also be referred to as a bypass state for that module. This bypass state can be initiated when a fault is detected in that module or when a system fault is detected that warrants shutting off multiple (or all) modules in the array or system. The module fault can be detected by LCD 114, and the control switching signal of converter 202 can be set to initiate the bypass state without intervention of MCD 112. Alternatively, fault information for a particular module can be communicated by LCD 114 to MCD 112, which can then make a decision on whether to initiate the bypass state and, if so, can communicate a command to initiate the bypass state to the LCD 114 associated with the faulty module, at which point the LCD 114 can output a switching signal to initiate the bypass state.

[0070] In embodiments in which the module 108 includes more than two energy sources 206, the converters 202B and 202C may be scaled accordingly, with each additional energy source 206B coupled to an additional IO port that leads to an additional switch circuit portion 602A or 602B, depending on the needs of that particular energy source. For example, the dual source converter 202 may include both switch portions 202A and 202B.

[0071] A module 108 with multiple energy sources 206 can perform additional functions, such as energy sharing between the energy sources 206, energy capture from within the application (e.g., regenerative braking), charging a primary energy source with a secondary energy source even when the overall system is in a discharged state, and active filtering of the module output. Active filtering functions can also be performed in modules with conventional electrolytic capacitors instead of secondary energy sources. Examples of these functions are described in more detail in International Application No. PCT / US20 / 25366, filed March 27, 2020, entitled "Module-Based Energy Systems Capable of Cascaded and Interconnected Configurations, and Methods Related Thereto," and International Application No. WO 2019 / 183553, filed March 22, 2019, entitled "Systems and Methods for Power Management and Control," both of which are incorporated by reference in their entireties for all purposes.

[0072] Each module 108 can be configured to supply one or more auxiliary loads with one or more energy sources 206. An auxiliary load is a load that requires a lower power rating than the primary load 101. Examples of auxiliary loads can include, for example, the on-board electrical network of an EV, including, but not limited to, the EV's HVAC system, heating system, DC / DC converter, etc. A load in the system 100 can be, for example, one phase of the EV motor or the electrical grid. This embodiment can allow for complete decoupling between the electrical characteristics of the energy source (terminal voltage and current) and the electrical characteristics of the load.

[0073] FIG. 3C is a block diagram illustrating an example embodiment of a module 108C configured to provide power to a first auxiliary load 301 and a second auxiliary load 302. The module 108C includes an energy source 206, an energy buffer 204, and a converter 202B coupled in a manner similar to that of FIG. 3B. The first auxiliary load 301 requires a voltage equivalent to that provided by the source 206. The load 301 is coupled to IO ports 3 and 4 of the module 108C, which are coupled to ports IO1 and IO2 of the source 206. The source 206 can output power to both the power connection 110 and the load 301. The second auxiliary load 302 requires a constant voltage lower than that of the source 206. The load 302 is coupled to IO ports 5 and 6 of the module 108C, which are coupled to ports IO5 and IO2, respectively, of the converter 202B. The converter 202B is coupled to a coupled inductor L coupled to port IO5 (FIG. 6B). C The energy provided by the source 206 can be delivered to the load 302 through the switch portion 602 of the converter 202B. Assuming that the load 302 has an input capacitor (if not, a capacitor can be added to the module 108C), the switches S1 and S2 are commutated to couple the coupling inductor L CThe voltage and current of the source 206 can be adjusted to produce a stable constant voltage across the load 302. This adjustment allows the voltage of the source 206 to be stepped down to a lower voltage than is required by the load 302.

[0074] Thus, module 108C can be configured to supply one or more first auxiliary loads in the manner described with respect to load 301, with the one or more first loads coupled to IO ports 3 and 4. Module 108C can also be configured to supply one or more second auxiliary loads in the manner described with respect to load 302. If there are multiple second auxiliary loads 302, then for each additional load 302, module 108C can be scaled with additional dedicated module output ports (such as 5 and 6), additional dedicated switch sections 602, and additional converter IO ports coupled to the additional sections 602.

[0075] Thus, energy source 206 can supply power to any number of auxiliary loads (e.g., 301 and 302) as well as a corresponding portion of the system output power required by primary load 101. The power flow from source 206 to the various loads can be adjusted as needed.

[0076] The module 108 can be configured with two or more energy sources 206 (FIG. 3B) as needed and can be configured to supply first and / or second auxiliary loads (FIG. 3C) by adding a switch portion 602 and converter port IO5 for each additional energy source 206B or second auxiliary load 302. Additional module IO ports (e.g., three, four, five, six) can be added as needed. The module 108 can also be configured as an interconnection module to exchange energy between two or more arrays, two or more packs, or two or more systems 100 (e.g., for balancing), as described further herein. This interconnection functionality can likewise be combined with multiple source and / or multiple auxiliary load supply capabilities.

[0077] The control system 102 can perform various functions with respect to the components of the modules 108A, 108B, 108C. These functions can include managing the utilization (usage) of each energy source 206, protecting the energy buffer 204 from overcurrent, overvoltage, and high temperature conditions, and controlling and protecting the converter 202.

[0078] For example, to manage (e.g., adjust by increasing, decreasing, or maintaining) the utilization of each energy source 206, the LCD 114 can receive one or more monitored voltages, temperatures, and currents from each energy source 206 (or monitoring circuitry). The monitored voltages can be at least one, and preferably all, of the voltage of each basic component independent of the other components of the source 206 (e.g., individual battery cells, HED capacitors, and / or fuel cells), or the voltage of the basic components as a whole (e.g., the voltage of a battery array, HED capacitor array, and / or fuel cell array). Similarly, the monitored temperatures and currents can be at least one, and preferably all, of the temperature and current of each basic component independent of the other components of the source 206, or the temperature and current of the basic components as a whole, or any combination thereof. The monitoring signal can be status information that enables the LCD 114 to one or more of: calculate or determine the actual capacity, actual state of charge (SOC) and / or state of health (SOH) of a base component or group of base components; set or output a warning or alarm indication based on the monitored and / or calculated status information; and / or transmit status information to the MCD 112. The LCD 114 can receive module control information (e.g., modulation index, synchronization signal) from the MCD 112 and use this module control information to generate switch signals for the converter 202 that manage the utilization of the source 206.

[0079] To protect the energy buffer 204, the LCD 114 can receive one or more monitored voltages, temperatures, and currents from the energy buffer 204 (or a monitoring circuit). The monitored voltages are monitored by each basic component (e.g., C EB , C EB1 , C EB2 , L EB1 , L EB2 , D EB ), or the voltage of the basic components or buffer 204 as a whole (e.g., between IO1 and IO2 or between IO3 and IO4). Similarly, the monitored temperature and current can be at least one, and preferably all, of the temperature and current of each basic component of buffer 204 independent of other components, or the temperature and current of the basic components of buffer 204 as a whole, or any combination thereof. The monitored signal can be status information that enables LCD 114 to one or more of: set or output a warning or alarm indication, communicate status information to MCD 112, or control converter 202 to adjust (increase or decrease) the utilization of source 206 and module 108 as a whole for buffer protection.

[0080] To control and protect the converter 202, the LCD 114 can receive module control information (e.g., a modulated reference signal, or a reference signal and a modulation index) from the MCD 112, which can be used in the LCD 114's PWM techniques to generate control signals for each switch (e.g., S1-S6). The LCD 114 can receive a current feedback signal from a current sensor in the converter 202, which can be used for overcurrent protection along with one or more fault status signals from the converter switch driver circuitry (not shown), which can carry information about the fault status (e.g., short-circuit or open-circuit failure mode) of all switches in the converter 202. Based on this data, the LCD 114 can determine the combination of switching signals to apply to manage the utilization of the module 108, potentially bypassing or disconnecting the converter 202 (and the entire module 108) from the system 100.

[0081] When controlling module 108C supplying a second auxiliary load 302, LCD 114 displays one or more monitored voltages (e.g., the voltage between IO ports 5 and 6) and one or more monitored currents (e.g., the current in load 302, the coupled inductor L C Based on these signals, the LCD 114 can adjust the switching periods of S1 and S2 (e.g., by adjusting the modulation index or the reference waveform) to control (and stabilize) the voltage of the load 302.

[0082] Cascaded Energy System Topology Example Two or more modules 108 can be coupled in a cascaded array that outputs a voltage signal formed by superimposing the individual voltages generated by each module 108 in the array. FIG. 7A is a block diagram illustrating an example topology embodiment for system 100 in which N modules 108-1, 108-2...108-N are coupled in series to form a series array 700. In this embodiment and all embodiments described herein, N can be any integer greater than or equal to 1. Array 700 includes a first system IO port SIO1 and a second system IO port SIO2, between which an array output voltage is generated. Array 700 can be used as a DC or single-phase AC energy source for DC or AC single-phase loads connectable to SIO1 and SIO2 of array 700. FIG. 8A is a voltage versus time plot illustrating an example output signal generated by a single module 108 having a 48-volt energy source. FIG. 8B is a voltage versus time plot illustrating an example single-phase AC output signal generated by an array 700 having six 48V modules 108 coupled in series.

[0083] System 100 can be arranged in a variety of different topologies to meet diverse application needs. System 100 can supply polyphase power (e.g., two-phase, three-phase, four-phase, five-phase, six-phase, etc.) to a load by using multiple arrays 700, with each array capable of generating an AC output signal having a different phase angle.

[0084] FIG. 7B is a block diagram illustrating a system 100 in which two arrays 700-PA and 700-PB are coupled. Each array 700 is one-dimensional and formed by a series connection of N modules 108. Each of the two arrays 700-PA and 700-PB can generate a single-phase AC signal, with the two AC signals having different phase angles PA and PB (e.g., 180 degrees apart). IO port 1 of module 108-1 in each array 700-PA and 700-PB can form or be connected to system IO ports SIO1 and SIO2, respectively, which can serve as the first output of each array that can supply two-phase power to a load (not shown). Alternatively, ports SIO1 and SIO2 can be connected to supply single-phase power from the two parallel arrays. IO port 2 of module 108-N of each array 700-PA and 700-PB may serve as a second output of each array 700-PA and 700-PB, on the opposite side of the array from system IO ports SIO1 and SIO2. These IO ports 2 may also be combined at a common node, which may optionally be used for an additional system IO port SIO3, if desired, and may serve as a neutral conductor. This common node may be referred to as the rail, and IO port 2 of module 108-N of each array 700 may be said to be on the rail side of the array.

[0085] 7C is a block diagram illustrating the system 100 in which three arrays 700-PA, 700-PB, and 700-PC are coupled. Each array 700 is one-dimensional and formed by a series connection of N modules 108. Each of the three arrays 700-PA, 700-PB, and 700-PC can generate a single-phase AC signal, with the three AC signals having different phase angles PA, PB, and PC (e.g., 120 degrees apart). IO port 1 of module 108-1 in each array 700-PA, 700-PB, and 700-PC can form or be connected to system IO ports SIO1, SIO2, and SIO3, respectively, which can supply three-phase power to a load (not shown). IO port 2 of modules 108-N of each array 700-PA, 700-PB, and 700-PC are joined at a common node, which can optionally be used for an additional system IO port SIO4, if desired, and can function as a neutral conductor.

[0086] 7B and 7C can be extended to systems 100 that generate power in even more phases. For example, a non-exhaustive list of additional examples includes a system 100 having four arrays 700, each configured to generate a single-phase AC signal having a different phase angle (e.g., 90 degree intervals), a system 100 having five arrays 700, each configured to generate a single-phase AC signal having a different phase angle (e.g., 72 degree intervals), and a system 100 having six arrays 700, each configured to generate a single-phase AC signal having a different phase angle (e.g., 60 degree intervals).

[0087] The system 100 can be configured such that the arrays 700 are interconnected at electrical nodes between the modules 108 within each array. Figure 7D is a block diagram illustrating the system 100 with three arrays 700-PA, 700-PB, and 700-PC coupled in a combined series and delta configuration. Each array 700 includes a first series connection of M modules 108 (where M is 2 or greater) and a second series connection of N modules 108 (where N is 2 or greater). The delta configuration is formed by the interconnections between the arrays and can be located in any desired location. In this embodiment, IO port 2 of module 108-(M+N) of array 700-PC is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PA, IO port 2 of module 108-(M+N) of array 700-PB is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PC, and IO port 2 of module 108-(M+N) of array 700-PA is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PB.

[0088] FIG. 7E is a block diagram illustrating system 100 in which three arrays 700-PA, 700-PB, and 700-PC are coupled in a combined series and delta configuration. This embodiment is similar to that of FIG. 7D , except for the cross-connections. In this embodiment, IO port 2 of module 108-M of array 700-PC is coupled to IO port 1 of module 108-1 of array 700-PA, IO port 2 of module 108-M of array 700-PB is coupled to IO port 1 of module 108-1 of array 700-PC, and IO port 2 of module 108-M of array 700-PA is coupled to IO port 1 of module 108-1 of array 700-PB. The arrangements of FIGS. 7D and 7E can be implemented with as few as two modules per array 700. Combining the delta and series configurations allows for an effective exchange of energy between all modules 108 in the system and the phases of the power grid or load (phase-to-phase balancing), and also allows for a reduction in the total number of modules 108 in the array 700 to achieve the desired output voltage.

[0089] In the embodiments described herein, it is advantageous for the number of modules 108 to be the same in each array 700 in system 100, but this is not required, and different arrays 700 can have different numbers of modules 108. Furthermore, each array 700 can have modules 108 that are all configured the same (e.g., all modules 108A, all modules 108B, all modules 108C, etc.), or can have modules 108 that are configured differently (e.g., one or more modules 108A, one or more modules 108B, and one or more modules 108C, etc.). Thus, the range of topologies for system 100 covered herein is broad.

[0090] Control Methodology Examples As previously mentioned, control of the system 100 can be achieved according to a variety of methodologies, including hysteresis and PWM. Some examples of PWM include space vector modulation and sinusoidal pulse width modulation, where the switching signals for the converter 202 are generated using a phase-shifted carrier technique that continuously rotates the utilization of each module 108 to evenly distribute power among them.

[0091] 8C-8F are plots illustrating an example embodiment of a phase-shifted PWM control methodology that can generate multi-level output PWM waveforms using incrementally shifted two-level waveforms. An X-level PWM waveform can be created by summing (X-1) / 2 two-level PWM waveforms. These two-level waveforms can be generated by comparing a reference waveform Vref with a carrier wave incrementally shifted by 360° / (X-1). The carrier wave is triangular, although this embodiment is not limited thereto. A nine-level example is shown in FIG. 8C (using four modules 108). The carrier wave is incrementally shifted by 360° / (9-1)=45° and compared to Vref. The resulting two-level PWM waveform is shown in FIG. 8E. These two-level waveforms may be used as switching signals for the semiconductor switches (e.g., S1-S6) of the converter 202. As an example, referring to FIG. 8E, for a one-dimensional array 700 including four modules 108 each having a converter 202, the 0° signal is for controlling S3 of the first module 108-1, the 180° signal is for S6, the 45° signal is for S3 of the second module 108-2, the 225° signal is for S6, the 90° signal is for S3 of the third module 108-3, the 270° signal is for S6, the 135° signal is for S3 of the fourth module 108-4, and the 315° signal is for S6. The signal for S3 is complementary to S4, and the signal for S5 is complementary to S6, with sufficient dead time to avoid shoot-through in each half-bridge. FIG. 8F shows an example of a single-phase AC waveform generated by superimposing (summing) the output voltages from four modules 108.

[0092] Another approach is to use both positive and negative reference signals on the first (N-1) / 2 carriers. A nine-level example is shown in FIG. 8D. In this example, the 0° to 135° switching signal (FIG. 8E) is generated by comparing +Vref to the 0° to 135° carrier in FIG. 8D, and the 180° to 315° switching signal is generated by comparing -Vref to the 0° to 135° carrier in FIG. 8D. However, the comparison logic in the latter case is reversed. Other techniques, such as a state machine decoder, may be used to generate the gate signals for the switches in converter 202.

[0093] In embodiments of a multi-phase system, the same carrier wave can be used for each phase, or the set of carrier waves can be shifted as a whole for each phase. For example, in a three-phase system with a single reference voltage (Vref), each array 700 can use the same number of carrier waves with the same relative offset, as shown in FIGS. 8C and 8D, but the carrier wave for the second phase is shifted 120 degrees relative to the carrier wave for the first phase, and the carrier wave for the third phase is shifted 240 degrees relative to the carrier wave for the first phase. If different reference voltages are available for each phase, the reference voltages can carry phase information, and the same carrier wave can be used for each phase. While the carrier frequency is often fixed, in some example embodiments, the carrier frequency can be adjusted, which can help reduce losses in the EV motor under high current conditions.

[0094] The appropriate switching signals may be provided to each module by the control system 102. For example, the MCD 112 may provide Vref and an appropriate carrier signal to each LCD 114, depending on the module 108 or group of modules 108 that each LCD 114 controls, and that LCD 114 may generate the switching signals. Alternatively, all carrier signals may be provided to all LCDs 114 in the array, with that LCD selecting the appropriate carrier signal.

[0095] The relative utilization of each module 108 can be adjusted based on the status information to balance one or more parameters, as described herein. Parameter balancing can include adjusting utilization to minimize the variance of a parameter over time compared to a system without individual module utilization adjustment. Utilization can be the relative amount of time a module 108 is discharging when the system 100 is in a discharging state, or the relative amount of time a module 108 is charging when the system 100 is in a charging state.

[0096] As described herein, modules 108 can be balanced relative to other modules in an array 700, which may be referred to as intra-array or intraphase balancing, and different arrays 700 can be balanced relative to each other, which may be referred to as inter-array or interphase balancing. Arrays 700 of different subsystems can also be balanced relative to each other. The control system 102 can simultaneously perform any combination of intra-phase balancing, inter-phase balancing, utilization of multiple energy sources within a module, active filtering, and auxiliary load supply.

[0097] 9A is a block diagram illustrating an example embodiment of an array controller 900 of a control system 102 for a single-phase AC or DC array. The array controller 900 may include a peak detector 902, a divider 904, and an intra-phase (or intra-array) balance controller 906. The array controller 900 may receive as inputs a reference voltage waveform (Vr) and status information (e.g., state of charge (SOCi), temperature (Ti), capacity (Qi), and voltage (Vi)) for each of the N modules 108 in the array and generate as outputs a normalized reference voltage waveform (Vrn) and a modulation index (Mi). The peak detector 902 detects the peak (Vpk) of Vr, which may be specific to the phase on which the controller 900 is operating with and / or without balancing. The divider 904 generates Vrn by dividing Vr by the detected Vpk. The intra-phase balance controller 906 uses Vpk along with status information (eg, SOCi, Ti, Qi, Vi, etc.) to generate a modulation index Mi for each module 108 in the array 700 being controlled.

[0098] The modulation index and Vrn can be used to generate switching signals for each converter 202. The modulation index is a number between zero and one, inclusive. For a particular module 108, the normalized reference Vrn can be modulated or scaled with Mi, and this modulated reference signal (Vrnm) can be used as Vref (or −Vref) according to the PWM techniques described with respect to FIGS. 8C-8F or other techniques. In this manner, the modulation index can be used to control the PWM switching signals provided to the converter switching circuits (e.g., S3-S6 or S1-S6) and thus regulate the operation of each module 108. For example, a module 108 controlled to maintain normal or full operation may receive a Mi of 1, a module 108 controlled below normal or full operation may receive a Mi less than 1, and a module 108 controlled to cease power output may receive a Mi of 0. This can be done in a variety of ways by the control system 102, such as by having the MCD 112 output Vrn and Mi to the appropriate LCD 114 for modulation and switch signal generation, by having the MCD 112 perform the modulation and output the modulated Vrnm to the appropriate LCD 114 for switch signal generation, or by having the MCD 112 perform the modulation and switch signal generation and output the switch signal directly to the LCD or converter 202 of each module 108. Vrn can be transmitted continuously, and Mi is transmitted at regular intervals, such as once per Vrn period or once per minute.

[0099] The controller 906 can use any type or combination of types of status information described herein (e.g., SOC, temperature (T), Q, SOH, voltage, current) to generate Mi for each module 108. For example, using SOC and T, a module 108 can have a relatively high Mi if it has a relatively high SOC and a relatively low temperature compared to other modules 108 in the array 700. A relatively low SOC or a relatively high T will result in that module 108 having a relatively low Mi and being less utilized than other modules 108 in the array 700. The controller 906 can determine Mi such that the sum of the module voltages does not exceed Vpk. For example, Vpk can be the sum of the products of the voltages of the sources 206 of each module and the Mi for that module (e.g., Vpk=M1V1+M2V2+M3V3...+M N V N , etc.) Different combinations of modulation indices and therefore respective voltage contributions by the modules may be used, but the total generated voltage should remain the same.

[0100] The controller 900 can control operation to maintain or converge, if not balanced, the SOC of the energy source(s) within each module 108, and / or maintain or converge, if not balanced, the temperature of the energy source(s) or other components (e.g., energy buffers) within each module, to the extent that it does not prevent the system from achieving its power output requirements at any given time (e.g., during maximum acceleration of an EV). Power flow into and out of modules can be adjusted so that capacitance differences between sources do not cause SOC deviations. Balancing SOC and temperature indirectly balances SOH. While voltage and current can be balanced directly, if desired, in many embodiments, the primary goal of the system is balancing SOC and temperature, and balancing SOC can result in voltage and current balance in a highly symmetrical system where modules have similar capacitances and impedances.

[0101] Since it may not be possible to balance all parameters, e.g., balancing operating characteristics, simultaneously (e.g., balancing one parameter may unbalance another), a combination of balancing any two or more parameters (SOC, T, Q, SOH, V, I) may be applied with priority given to one depending on the application requirements. Balancing may prioritize SOC over other parameters (T, Q, SOH, V, I), with the exception of when any of the other parameters (T, Q, SOH, V, I) reaches a severe unbalanced condition outside the threshold.

[0102] Balancing between arrays 700 of different phases (or arrays of the same phase, e.g., when parallel arrays are used) can occur simultaneously with intra-phase balancing. FIG. 9B shows an example embodiment of an Ω-phase (or Ω-array) controller 950 configured for operation in an Ω-phase system 100 having at least an Ω-array 700 (where Ω is any integer greater than 1). The controller 950 may include one inter-phase (or inter-array) controller 910 and intra-Ω-phase balance controllers 906-PA...906-PΩ for phases PA through PΩ, as well as peak detectors 902 and dividers 904 ( FIG. 9A ) for generating normalized reference values ​​VrnPA through VrnPΩ from each phase-specific reference value VrPA through VrPΩ. The intra-phase controller 906 may generate Mi for each module 108 of each array 700, as described with respect to FIG. 9A . The phase-to-phase balance controller 910 is configured or programmed to balance the items of the modules 108 throughout the multidimensional system, for example, between arrays of different phases. This can be achieved by injecting a common mode into the phases (e.g., neutral point shifting), or by using interconnection modules (described herein), or both. Common mode injection involves introducing a phase and amplitude shift into the reference signals VrPA-VrPΩ to generate normalized waveforms VrnPA-VrnPΩ to compensate for imbalances within one or more arrays, as further described in International Application No. PCT / US20 / 25366 (incorporated herein by reference).

[0103] Controllers 900 and 950 (and balance controllers 906 and 910) can be implemented in hardware, software, or a combination thereof within control system 102. Controllers 900 and 950 can be implemented within MCD 112, can be partially or fully distributed among LCD 114, or can be implemented as individual controllers separate from MCD 112 and LCD 114.

[0104] Interconnect (IC) Module Example Modules 108 can be connected between modules of different arrays 700 for the purpose of exchanging energy between arrays, acting as sources for auxiliary loads, or both. Such modules are referred to herein as interconnect (IC) modules 108. The IC modules 108 can be implemented in any of the module configurations previously described (108A, 108B, 108C) and other configurations described herein. The IC modules 108 can include any number of one or more energy sources, optional energy buffers, switch circuitry for supplying energy to one or more arrays and / or powering one or more auxiliary loads, control circuitry (e.g., local controllers), and monitoring circuitry for collecting status information about the IC module itself or its various loads (e.g., SOC of the energy source, temperature of the energy source or energy buffer, capacity of the energy source, SOH of the energy source, voltage and / or current measurements associated with the IC module, voltage and / or current measurements associated with the auxiliary loads, etc.).

[0105] FIG. 10 is a block diagram illustrating an example embodiment of a system 100 capable of generating Ω-phase power using Ω arrays 700-PA through 700-PΩ, where Ω can be any integer greater than 1. In this and other embodiments, IC module 108IC may be installed on the rail side of array 700 such that the array 700 to which it is connected (in this embodiment, arrays 700-PA through 700-PΩ) is electrically connected between the module 108IC and the output to the load (e.g., SIO1 through SIOΩ). Here, module 108IC has an ΩIO port for connecting to IO port 2 of each module 108-N of array 700-PA through 700-PΩ. In the configuration shown here, module 108IC can provide phase-to-phase balancing by selectively connecting one or more energy sources of module 108IC to one or more of arrays 700-PA through 700-PΩ (or connecting to no outputs or equally to all outputs if phase-to-phase balancing is not required). The system 100 can be controlled by a control system 102 (not shown, see FIG. 1A).

[0106] Examples of Second Life Energy Sources The energy source 206 described herein can be used in the system 100 described herein in both first-life and second-life applications. The first-life of the source 206 is the original application in which the source 206 is used. For example, a first-life application is the first implementation of the source 206 used by the first customer after original manufacture (not refurbishment) of the source 206. A user of the source 206 in its first life would typically have received the source 206 from a manufacturer, distributor, or original equipment manufacturer (OEM). Batteries 206 used in first-life applications will typically have the same electrochemistry (e.g., the same variant of lithium-ion electrochemistry (e.g., LFP, NMC)), the same nominal voltage, and minimal (e.g., 5% or less) capacity variation across the pack or system. Using an energy storage system with batteries 206 in their first-life applications will result in batteries 206 having a longer lifespan in their first-life applications, and when removed from their first-life applications, the battery 206 will experience a capacity degradation comparable to that of a battery in a first-life application without an energy storage system.

[0107] As used herein, a "second-life" application is any use or implementation (e.g., secondary implementation, tertiary implementation, quaternary implementation, etc.) of a source 206 after its first-life application. A second-life energy source refers to any energy source (e.g., a battery or HED capacitor) implemented in the second-life application of that source.

[0108] An example of a first-life application for battery 206 is in an energy storage system for an EV. Subsequently, at the end of its life (e.g., after 100,000 miles of driving or after a threshold amount of degradation of the batteries in that battery pack), battery 206 can be removed from the battery pack, optionally repaired and tested, and then implemented into a second-life application, such as use in a stationary energy storage system (e.g., a residential, commercial, or industrial energy buffer, an EV charging station energy buffer, a renewable source (e.g., wind, solar, hydro), energy buffer, etc.) or another mobile energy storage system (e.g., a battery pack for an electric vehicle, bus, train, or truck). Similarly, the first-life application can be an initial stationary application, and the second-life application can be a stationary or mobile application.

[0109] For second-life applications, sources 206 can be selected and / or utilized by system 100 to minimize (or at least reduce) any differences in initial capacity and nominal voltage. For example, sources 206 having a capacitance difference of 5% or more can be included in system 100 and operated to supply energy to a load. In another example, an operator or automated system can select sources 206 for system 100 whose capacitance difference is within a threshold, e.g., to reduce the initial capacity difference between sources 206 in the system. If a module 108 is compatible with both first-life and second-life applications (e.g., with or without reconfiguration), the module 108 can be selected for second-life applications based on the capacity difference of the sources 206 of the module 108.

[0110] System 100 can individually adjust the utilization of each source 206, so that the sources 206 within system 100 or a pack of system 100 are relatively balanced in terms of SOC or total charge (SOC x capacity) when the pack or system 100 is discharged, even though the sources 206 within system 100 may have widely varying capacities. Similarly, system 100 can maintain balance when the pack or system 100 is charged. Sources 206 may vary not only in capacity, but also in nominal voltage, power rating, electrochemistry type (e.g., a combination of LFP and NMC batteries), etc. Thus, system 100 can be used such that all modules 206 within system 100 or each pack of system 100 are second-life energy sources having various combinations of different characteristics (or such that a combination of first-life and second-life energy sources is used).

[0111] In one example, the system 100 may include a second-life energy source 206 (and optionally one or more first-life energy sources 206) having an energy capacity variation of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0112] In another example, the system 100 may include a second-life energy source 206 (and optionally one or more first-life energy sources 206) having an energy capacity / mass density variation of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0113] In another example, the system 100 may include a second-life energy source 206 (and optionally one or more first-life energy sources 206) having a peak power / mass density variation of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0114] In another example, the system 100 may include a second-life energy source 206 (and optionally one or more first-life energy sources 206) having a nominal voltage variation of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0115] In another example, the system 100 may include a second-life energy source 206 (and optionally one or more first-life energy sources 206) having an operating voltage variation of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0116] In another example, the system 100 may include a second-life energy source 206 (and optionally one or more first-life energy sources 206) having a maximum specified current rise time variation of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0117] In another example, the system 100 may include a second-life energy source 206 (and optionally one or more first-life energy sources 206) having a specified peak current variation of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0118] A variation of X% (e.g., 5% or more, or 5-30%) can be caused by a variation within the system 100 between the module 108 exhibiting the highest value and the module 108 exhibiting the lowest value for a given parameter. For example, a variation of 5% or more in capacity can be caused by a system 100 in which the module 108 with the lowest capacity source 206 has a capacity that is 95% or less of the capacity of the module 108 with the highest capacity source 206. For all embodiments and all parameters disclosed herein, the time at which a system 100 having one or more second-life sources meets the X% variation condition for that parameter can be upon installation of the system 100, upon commissioning of the system 100, after replacing a source 206 with another source 206, after operating the system 100 for 10 hours or more, after operating the system 100 for 100 hours or more, after operating the system 100 for 1000 hours or more, and / or after operating the system 100 for 10,000 hours or more. For example, a system 100 may exhibit zero capacity variation during commissioning, but after 1000 hours of operation, exhibit a capacity variation of 5% or more, reflecting the ability of an embodiment of the system 100 to continue operation while accounting for increasing capacity differences between sources 206 over operating time.

[0119] In another example, system 100 may include second-life energy sources 206 (and optionally one or more first-life energy sources 206) that vary in electrochemical type, such as a combination of lithium-ion and non-lithium-ion batteries, or different types of lithium-ion batteries (e.g., any combination of NMC, LFP, LTO, or other lithium-ion battery types).

[0120] System 100 can include a second-life energy source 206 (and optionally one or more first-life energy sources 206) having any combination of the characteristics presented in the preceding examples.

[0121] Example of a Subsidiary Signal Conversion Device (SSCD) Example embodiments of a modular energy system 100 including an array 700 for supplying AC power to one or more AC loads, e.g., a primary AC load, and a supplemental signal conversion device (SSCD) for supplying DC power to DC loads, e.g., auxiliary DC loads, are described with reference to Figures 11-15K. These embodiments may be implemented in all aspects of the system 100 described with reference to Figures 1A-10F, unless otherwise noted or logically impossible. As such, many of the variations contemplated herein with respect to each of the following SSCD embodiments will not be repeated.

[0122] 11 is a block diagram of an example embodiment of a modular energy system 100 having a module pack 1110 and an SSCD 1120. The module pack 1110 includes a plurality of arrays 700 that can be arranged and / or connected in various ways as described herein to provide power to one or more first loads 101-1, 101-2 and SSCDs 1120 for providing power to one or more second loads 301-1...301-N. The first loads 101-1, 101-2 can be referred to as primary loads, and the second loads can be referred to as auxiliary loads.

[0123] The module pack 1110 can include any number of arrays 700, and each array 700 can include any number of modules 108. The module pack 1110 can be in the form of a pack, and as described above, the common housing that holds the modules 108 can be referred to as a pack. However, in some embodiments, the arrays 700 of the module pack 1110 can be arranged as multiple packs, each housed in a separate individual housing, or external to the pack (without a common housing), or as multiple sub-packs that may or may not be housed in a common housing. A sub-pack can refer to a group of arrays 700 that are combined with one or more other sub-packs to form the module pack 1110. For example, a sub-pack can be a multi-phase sub-pack with one or more arrays for each phase, or a single-phase sub-pack with one or more arrays for a single phase. Each sub-pack may or may not be individually housed. Examples of arrangements of arrays 700 within the housing 230 are shown in Figures 12A-12E and described below.

[0124] Although shown outside the module pack 1110, the SSCD 1120 and / or SSCD controller 1122 can be included in the same housing 230 as the array 700 of the module pack 1110. In some embodiments, the SSCD 1120 and SSCD controller 1122 are in a common housing 230 that is separate from the module pack 1110, in different housings 230, or without a housing 230.

[0125] The module pack 1110 is coupled to one or more loads 101. In some embodiments, each load 101 is an AC load powered by an AC signal provided by the module pack 1110. Each load 101 can be a single-phase AC load or a poly-phase AC load. An array 700 of module packs 1110 can be coupled to the single-phase AC load 101. Multiple arrays 700 of module packs 1110 can be coupled to the poly-phase AC load 101, e.g., one array 700 for each phase if each array 700 coupled to the load 101 has a different phase.

[0126] In the illustrated embodiment, the module pack 1110 includes six arrays: array 700-A, 700-B, 700-C, 700-U, 700-V, and 700-W, where array 700-A is coupled to array 700-U, array 700-B is coupled to array 700-V, and array 700-C is coupled to array 700-W. Coupling the arrays 700 in this manner allows for flexible configurations where an array 700 can power multiple AC loads, or two arrays 700 can be coupled to provide additional power to a phase of the load 101 in addition to powering an auxiliary load. As described in more detail below, each array 700 can include a first port and a second port between which an AC signal is generated by the array 700. Depending on the configuration and / or operation of the array 700, the first port may be a phase port and the second port may be a neutral port, or the first port may be a neutral port and the second port may be a phase port. A phase port is a port at which the array 7000 outputs a signal of varying amplitude, and a neutral port is a port that is maintained at a neutral potential, e.g., at or near ground potential.

[0127] The neutral ports of two or more arrays 700 can be coupled at a common neutral point (or node) for the two or more arrays 700, or they can form a common neutral point (or node) for the arrays 700. For example, the neutral port of array 700-A can be coupled to the neutral port of array 700-U at the common neutral point (or node) between arrays 700-A and 700-U. Each other pair of arrays 700 can be coupled in the same manner.

[0128] In some embodiments, two or more arrays can be coupled to form a larger array that outputs a single-phase AC signal. For example, array 700-A and array 700-U can be coupled to output a single-phase AC signal. In this example, arrays 700-A and 700-U can be configured such that a phase port of one array 700-A or 700-U is coupled to a neutral port of the other array 700-A or 700-U.

[0129] Each pair of arrays 700 can be configured to jointly generate in-phase AC signals. For example, the AC signals output by arrays 700-A and 700-U can have a first phase angle, the AC signals output by arrays 700-B and 700-V can have a second phase angle, and the AC signals output by arrays 700-C and 700-W can have a third phase angle. The first phase angle can be offset 120 degrees from the second phase angle, which can be offset 120 degrees from the third phase angle, which can be offset from the first phase angle. Thus, module pack 1110 can be configured to output a three-phase AC signal to the phase terminals of arrays 700-A, 700-B, and 700-C and another three-phase AC signal to the phase terminals of arrays 700-U, 700-V, and 700-W. The two three-phase AC signals can be in phase or out of phase with each other.

[0130] In some embodiments, the three-phase outputs of arrays 700-A, 700-B, and 700-C can be coupled to one load 101-1 (e.g., a front axle motor), and the three-phase outputs of arrays 700-U, 700-V, and 700-W can be coupled to another load 101-2 (e.g., a rear axle motor). In some embodiments, the three-phase outputs of arrays 700-A, 700-B, and 700-C and the three-phase outputs of arrays 700-U, 700-V, and 700-W can be coupled to the same load 101-1. For example, this configuration can power an open-end winding motor (which may also be referred to as an open winding motor) load 101-1. In some embodiments, arrays 700-A and 700-U are combined to form large array 700-AU, arrays 700-B and 700-V are combined to form large array 700-BV, and arrays 700-C and 700-W are combined together to form large array 700-CW. In this embodiment, the three-phase outputs of the three large arrays 700-AU, 700-BV, and 700-CW can be combined to a single load 101-1. In this manner, the adjustable configuration of arrays 700-A through 700-W within module pack 1110 provides flexibility to power different loads 101-1 using the same module pack 1110.

[0131] A group of two or more arrays 700 coupled at their neutral ports or coupled between the neutral port of one array 700 and the phase ports of another array 700 can be referred to as a segment. As also shown in FIG. 12D , arrays 700-A and 700-U are a first segment, arrays 700-B and 700-V are a second segment, and arrays 700-C and 700-W are a third segment. Each of these segments includes two arrays 700, but a segment can include more than one array 700. For example, a module pack 1110 can include segments with four arrays each to power four loads 101, each powered by a single three-phase AC signal, or two loads 101, each powered by two three-phase AC signals. In these examples, only one load 101 is powered by each three-phase AC signal, but each three-phase AC signal can power multiple loads 101. For example, the phase terminals of arrays 700-A, 700-B, and 700-C can be coupled to multiple AC loads 101.

[0132] The module pack 1110 can also be configured to output polyphase AC signals other than three-phase AC signals. For example, the module pack 1110 can include six segments to output one or more six-phase AC signals. The module pack 1110 can also be configured to output more than two of the same polyphase signals. For example, the module pack 1110 can include one or more copies of the arrays 700-A through 700-W.

[0133] The module pack 1110 is communicatively coupled to the control system 102 via a communication path or link 1131. As described herein, the control system 102 may include an MCD 112 and a plurality of LCDs 114. The control system 102 may also include a controller 900 and / or a controller 950, for example, as part of the MCD 112 and / or LCD 114 or as separate components. For example, the control system 102 may include an MCD 112 for each array 700 of the module pack 1110, an MCD 112 for the entire array of the module pack 1110, an MCD 112 for each segment, and / or other arrangements of MCDs 112 for the modules 108 of the array 700. The control system 102 may also include an array controller 900 for each array 700, or a controller 950 for multiple arrays 700, such as, for example, a controller for all arrays 700 in a module pack 1110, or a controller 950 for each group of arrays 700 configured to output a three-phase signal (e.g., controllers 950 for arrays 700-A through 700-C and controllers 950 for arrays 700-U through 700-W). Various other arrangements of the MCD 112, LCD 114 controllers 900 and / or 950 may also be used.

[0134] The control system 102 may be contained in the same housing 230 as the array 700 of module packs 1110, or in a different housing. The control system 102 may also be distributed among multiple housings 230, for example, the LCD 114 may be housed in the same housing 230 as the modules 108, and the MCD 112, controllers 900 and / or 950 may be housed in one or more different housings 230.

[0135] As described herein, control system 102 is configured to control module 108 based on status information received from module 108. Control system 102 may also be configured to control module 108 based on external control information, e.g., processed external control information, received from SSCD controller 1122, as described in more detail below. Control system 102 may be communicatively coupled to SSCD controller 1122 via communication path or link 1133.

[0136] The SSCD controller 1122 is also communicatively coupled to the SSCD 1120 via a communication path or link 1132. The SSCD 1120 is configured to convert the AC signal from the module pack 1110 to a DC signal and output the DC signal to one or more loads 301 via one or more DC power buses 1136. The SSCD 1120 may be or include a rectifier circuit configured to convert the AC signal to a DC signal. The rectifier circuit may include a diode array and / or a filter circuit, as described in more detail below.

[0137] The module pack 1110 is coupled to the SSCD 1120 via a cable 1134 or other suitable group of conductors. The cable 1134 can have connectors of different configurations, as described in more detail below.

[0138] The SSCD controller 1122 can control the SSCD 1120 to adjust the DC signal output by the SSCD 1120. The SSCD 1120 can also be configured to balance one or more operating characteristics of the modules 108, the array 700, and / or subpacks of the module pack 1110. As described herein, these operating characteristics can include, for example, SOC, SOH, temperature, voltage, current, SOP, and / or SOE.

[0139] As described in more detail below, the SSCD controller 1122 can be configured to process external control information received from the external controller 104 and provide the processed external control information to the control system 102 via a communication path or link 1133 to adjust the DC signal output by the SSCD 1120 and / or control the SSCD 1120 to balance one or more operating characteristics. The SSCD controller 1122 can be communicatively coupled to the external controller 104 via a communication path or link 1135.

[0140] The SSCD controller 1122 can be configured to perform one or more types of balancing. The SSCD controller 1122 can be configured to perform subpack balancing among one or more types of subpacks of the module pack 1110. For example, the SSCD controller 1122 can be configured to balance one or more operational characteristics of a subpack including arrays 700-A through 700-C, which may be referred to as a multi-phase subpack, with one or more corresponding operational characteristics of a subpack including arrays 700-U through 700-W. In another example, the SSCD controller 1122 can be configured to balance one or more operational characteristics of a subpack including arrays 700-A and 700-U, which may be referred to as a segment subpack or simply a segment, as described above, with one or more corresponding operational characteristics of a subpack including arrays 700-B and 700-V and / or one or more corresponding operational characteristics of a subpack including arrays 700-C and 700-W.

[0141] The SSCD controller 1122 and / or control system 102 can be configured to determine operational characteristics of the array 700 and / or sub-packs of the array 700 based on the operational characteristics of the modules 108 in the array 700. The operational characteristics of the array 700 or sub-packs can include an aggregate value of the operational characteristics across the modules 108 in the array 700 or sub-packs. The aggregate value can be a sum or a measure of central tendency (e.g., mean or median) of the values ​​across the modules 108 in the array 700 or sub-packs. The modules 108 used in the aggregate value can include all modules 108 in the array 700 or sub-pack, or can include only the active modules 108 in the array 700 or sub-pack. The values ​​of inactive modules 108 that are bypassed can be ignored in some embodiments.

[0142] The module packs 1110 are also coupled to a charging source 150. The charging source 150 can be used to charge the energy sources 206 of the modules 108. As described in more detail below, the control system 102 (or SSCD controller 1122) can be configured to control components of the system 100, such as switches, to route the charging signals provided by the charging source 150 to the array 700 of module packs 1110.

[0143] The SSCD controller 1122 can be implemented in hardware, software, or a combination thereof. The SSCD controller 1122 can be implemented as a separate controller separate from or within the control system 102. For example, the SSCD controller 1122 can be a controller of the control system 102, or the operations described as being performed by the SSCD controller 1122 can be performed by the MCD(s) 112 and / or the LCD(s) 114 of the control system 102.

[0144] System 100 can be implemented to power loads 101 and 301 of an EV. In this example, load 101-1 and / or load 101-2 can be EV motors, and load 301 can be an auxiliary DC load of the EV. In the EV example, auxiliary DC load 301 can include, for example, an HVAC system of the EV, an on-board electrical network of the EV, a battery heater for a battery of module 108 of module pack 1110, a DC / DC converter(s), and / or other DC loads of the EV. System 100 can also be implemented in stationary applications to power stationary loads 101 and 301.

[0145] In an EV embodiment, the module pack 1110 can be configured to provide AC power to one or more EV motors 101 and to provide AC power to the SSCD 1120 for providing DC power to auxiliary DC loads 301. The auxiliary DC loads 301 can include power distribution units (PDUs) that provide power to other auxiliary loads 301. The PDU auxiliary loads 301 can include voltage and / or current converters that convert DC signals received from the SSCD 1120 to appropriate voltages and / or currents for those auxiliary loads 301. The converters can be DC / DC converters and / or DC / AC converters, depending on the auxiliary loads 301 coupled to the PDU 301.

[0146] When installed in an EV, the module pack 1110, SSCD 1120, control system 102, and SSCD controller 1122 can be arranged in a variety of configurations. For example, the SSCD 1120 and SSCD controller 1122 can be housed in a common housing 230, which can include one or more PDUs 301, be located near the PDU(s) 301, or be located within the PDU(s) 301. In another example, the module pack 1110 and SSCD 1120 can be housed in a common housing 230, which can also house the control system 102 and / or the SSCD controller 1122. This housing 230 can be located near the PDU(s) 301, for example, to reduce losses between the SSCD 1120 and one or more PDUs 301.

[0147] The module pack 1110 can be implemented in a variety of forms. For example, the module pack 1110 can be in the form of a flat battery pack or a tunnel battery pack. Including the SSCD 1120 within or near the housing 230 of the module pack 1112 can shorten signal routing between the voltage and current sensors of the SSCD 1120 and the control system 102 of the module pack 1110. In some embodiments, the SSCD 1120 is located within the PDU 301. In such embodiments, the location of the PDU 301 may be defined based on packaging constraints of the PDU 301. The PDU 301 can be installed near the charging port 1330 ( FIG. 13A ) with a short DC cable between the charging port 1330 and the SSCD 1120. One or more PDUs 301 can also be installed under the hood of the EV, under the cargo area of ​​the EV, or in other areas of the EV.

[0148] Some EVs (and other applications of system 100) include high-voltage DC loads and low-voltage DC loads. For example, an EV may include a DC load with a voltage level that is the same as or close to the voltage level of the EV's motor. The SSCD 1120 may be configured to output DC power having a voltage level that is the same as or similar to the AC power supplied to the motor(s) 101. This DC power may be supplied, for example, directly to the high-voltage DC loads 301. Furthermore, the PDU 301 may convert this DC power to a lower voltage level for the low-voltage DC loads 301.

[0149] In a specific example, some EV motors are configured to be powered by AC signals output by an inverter coupled to a 400V DC link. The inverter can be configured to output a 400VAC peak (310VAC RMS) line-to-line AC signal to the EV motor. Some of the EV's high-voltage DC loads operate at 400VDC, while some of the EV's low-voltage DC loads operate at 48VDC or 12VDC. The module pack 1110 can be configured to output 400VAC between the ports of each of the arrays 700-A, 700-B, and 700-C, and 400VAC between the ports of each of the arrays 700-U, 700-V, and 700-W. For an 800V motor, both of these AC signals can be routed to the motor. The SSCD 1120 can be configured to convert one or both of the 400 VAC output signals to 400 VDC for powering 400 VDC loads and / or the PDU to 48 VDC and / or 12 VDC for low-voltage DC loads. These voltage values ​​are provided to illustrate example EV embodiments only. The module pack 1110 can be configured to output higher and lower AC voltages, and the SSCD 1120 can be configured to convert these higher and lower AC voltages to various levels of DC voltage and regulate the DC voltage. Higher voltage values ​​can be used in embodiments configured for other mobile applications, such as trains, trams, ships, marine vessels, aircraft, and spacecraft, and / or in stationary applications.

[0150] The module pack 1110 and the SSCD 1120 can operate in a similar or identical manner in stationary applications. For example, the module pack 1110 can be configured to output AC power at appropriate voltage levels for the AC load 101 and / or the DC load 301. The SSCD 1120 can be configured to convert the AC power to DC power at the same or similar voltage levels for DC loads operating at these voltage levels. The PDU 301 can convert the DC voltage output by the SSCD 1120 to a different voltage and / or current level for the load 301 coupled to the PDU 301.

[0151] The module pack 1110 and SSCD 1120 can be configured to supply power to low-voltage loads, and the PDU 301 can convert the low voltage to a higher voltage for higher-voltage DC loads. For example, the module pack 1110 can be configured to output 120 VAC power, and the SSCD 1120 can be configured to convert the 120 VAC to 120 VDC or another appropriate voltage level. The PDU 301 can include a DC / DC converter configured to convert the 120 VDC to 400 VDC (or another voltage level) for the higher-voltage loads 301.

[0152] Using the array 700 of modules 108 in this manner provides a robust, modular power supply for a variety of applications. For example, if one or more modules 108 in the array 700 fail, the failed module can be bypassed to continue powering the load 101 and the load 301 without interruption. This is important in many applications, but particularly in mobile applications where failure of other types of EV batteries can result in loss of EV propulsion. Embodiments of the system 100 described herein are configured to maintain propulsion in the event of failure of one or more modules 108 and / or failure of the entire array 700. For example, if a failure in array 700-A renders motor 101-1 inoperable, motor 101-2 can still be powered by arrays 700-U, 700-V, and 700-W. Even if motor 101-1 is a front wheel drive motor that operates the front wheels of the EV and motor 101-2 is a rear wheel drive motor that operates the rear wheels of the EV, the EV can still be operated using rear wheel drive motor 101-2.

[0153] In another example, arrays 700-U, 700-V, and 700-W can be configured as redundant power sources for a single motor 101-1 that is normally powered by arrays 700-A, 700-B, and 700-C. In the event of a failure of one or more of arrays 700-A, 700-B, and 700-C, a single motor 101-2 can be powered by arrays 700-U, 700-V, and 700-W.

[0154] 12A-12E are block diagrams of example embodiments of module packs 1110. In these examples, each module pack 1110 includes six arrays 700-A-700-W arranged in three segments, but can be arranged to include other numbers of segments and / or other numbers of arrays per segment, as described herein.

[0155] 12A, arrays 700-A through 700-W of module pack 1110 are enclosed in housing 230. Arrays 700-A through 700-W may or may not be individually enclosed in individual housings within housing 230.

[0156] Each array 700 includes system I / O ports SIO1 and SIO2. Depending on the configuration and / or operation of the module pack 1110, the system I / O port SIO1 or SIO2 of one of the arrays 700 may be a phase port of the array 700, and the system I / O port SIO1 or SIO2 of the other of the arrays 700 may be a neutral port of the array 700.

[0157] System I / O port SIO2 of array 700-A is coupled to system I / O port SIO2 of array 700-U. This segment may be referred to as segment AU. System I / O port SIO2 of array 700-B is coupled to system I / O port SIO2 of array 700-V. This segment may be referred to as segment BV. System I / O port SIO2 of array 700-C is coupled to system I / O port SIO2 of array 700-W. This segment may be referred to as segment CW.

[0158] When system I / O port SIO2 of arrays 700-A and 700-U is the neutral port of arrays 700-A and 700-U, this coupling provides a common neutral point "N" for the segment including arrays 700-A and 700-U. When the ports SIO2 of the arrays of these segments are coupled, a similar neutral point is formed for segments BV and CW. In other embodiments, system I / O port SIO2 of one or more arrays 700-A through 700-W can be a phase port of the array(s). For example, system I / O port SIO2 of array 700-U can be a phase port of array 700-U. When coupled to the neutral port of array 700-A, a larger array can be formed that includes modules 108 from both arrays 700-A and 700-U.

[0159] Module pack 1110 also includes system I / O ports SIO1-SIO6 to which components external to module pack 1110 can be coupled. System I / O port SIO1 of module pack 1110 is coupled to system I / O port SIO1 of array 700-A. System I / O port SIO2 of module pack 1110 is coupled to system I / O port SIO1 of array 700-B. System I / O port SIO3 of module pack 1110 is coupled to system I / O port SIO1 of array 700-C. System I / O port SIO4 of module pack 1110 is coupled to system I / O port SIO1 of array 700-U. System I / O port SIO5 of module pack 1110 is coupled to system I / O port SIO1 of array 700-V. The system I / O port SIO6 of the module pack 1110 is coupled to the system I / O port SIO1 of the array 700-W. The system I / O ports SIO1 to SIO6 of the module pack 1110 can be installed inside or outside the housing 230.

[0160] 12B, arrays 700-A to 700-C are arranged in subpack ABC1111-1, and arrays 700-U to 700-V are arranged in subpack UVW1111-2. In this example, subpack 1111-1 is enclosed in housing 230-2, and subpack 1111-2 is enclosed in housing 230-3. These two housings 230-2 and 230-3 are enclosed in a common housing 230-1.

[0161] In this example, the subpack 1111 includes multiple arrays 700, e.g., an array 700 for each of multiple phases. Here, each subpack 1111 includes three arrays 700 for supplying three-phase AC power. By using subpacks 1111 enclosed in individual housings 230, the subpacks 1111 can be easily replaced in the event of failure or degradation of the subpack 1111 or its modules 108 or arrays 700. The system I / O ports SIO1 and SIO2 of the arrays 700 of each subpack 1111 can be located inside or outside the housing 230 of the subpack 1111 for coupling with the system I / O ports of the arrays 700 of another subpack 1111 and / or the system I / O ports of the module pack 1110.

[0162] 12C, this embodiment differs from the embodiment of FIG. 12B in that sub-packs 1111-1 and 1111-2 are enclosed in separate housings 230-2 and 230-3, respectively, but housings 230-2 and 230-3 are not enclosed in common housing 230-1. Here, system I / O ports SIO1 and SIO2 of array 700 can be coupled to system I / O ports of arrays 700 in other sub-packs 1111 and / or to components external to sub-pack 1111. For example, system IO port SIO2 of array 700-A in sub-pack 1111-1 can be coupled to system IO port SIO2 of array 700-U in sub-pack 1111-2, and system IO port IO1 of array 700-A can be coupled to external components.

[0163] 12B and 12C, each subpack 1111 can include system IO ports that are coupled to system IO ports of the arrays 700 contained in the subpack 1111. These system IO ports of the subpack 1111 can be located inside or outside the housing 230 of the subpack 1111 for coupling the arrays 700 of the subpack 1111 to other components.

[0164] 12D, module pack 1110 includes segment sub-packs 1112-1, 1112-2, and 1112-3 enclosed in individual housings 230-2, 230-3, and 230-4, respectively. Housings 230-2 through 230-4 are enclosed in a common housing 230-1 for module pack 1110.

[0165] Each segment subpack 1112 includes two arrays 700 with coupled system I / O ports SIO2. Similar to the embodiment of Figures 12A and 12B, the system IO ports of the arrays 700 are coupled to respective system IO ports of the module pack 1110. This embodiment allows for easy replacement of modular segments in the event of failure or degradation of a segment subpack 1112 or a module 108 or array 700 in the segment subpack 1112.

[0166] 12E, this embodiment differs from the embodiment of FIG. 12D in that segment subpacks 1112-1, 1112-2, and 1112-3 are enclosed in separate housings 230-2, 230-3, and 230-4, respectively, but housings 230-2 through 230-4 are not enclosed in common housing 230-1. Here, system I / O port SIO1 of array 700 of segment subpacks 1112 can be coupled to components external to segment subpacks 1112.

[0167] 12D and 12E, each segment subpack 1112 can include a system IO port that is coupled to a system IO port of an array 700 included in the subpack 1112. These system IO ports of the segment subpack 1112 can be located inside or outside the housing 230 of the segment subpack 1112 for coupling the array 700 of the segment subpack 1112 to other components.

[0168] The module pack 1110 and the SSCD 1120 can be configured in a variety of ways, each supporting different numbers and / or types of loads 101 and / or 301. Such configurations can be used with no or minimal modifications for different numbers and / or types of loads 101 and / or 301. Several example embodiments are shown in FIGS. 13A-15K and described below. While these embodiments are described in terms of powering a motor load 101 and an auxiliary load 301 in an EV, the embodiments can also be used to power motor loads in other mobile vehicles and loads in stationary applications.

[0169] 13A-13C are block diagrams of example embodiments of a modular energy system 100 having a module pack 1110 and an SSCD 1120 for powering primary and secondary loads. In particular, FIG. 13A illustrates an embodiment of the system 100 for powering two motors 101-1 and 101-2. FIG. 13B illustrates an embodiment of the system 100 for powering one motor 101-1. FIG. 13C illustrates an embodiment of the system 100 that can be selectively configured to power one or two motors 101-1.

[0170] 13A, system 100 includes a module pack 1110 coupled to an SSCD 1120 via a cable 1134. The module pack 1110 may be implemented using any embodiment of the module pack 1110 described herein unless otherwise noted or logically impossible. System 100 may include a control system 102, an SSCD controller 1122, and an external controller 104, although these components are omitted from FIGS. 13A-13C and will be described in more detail with reference to FIGS. 13H and 13K.

[0171] Cable 1134 includes connectors 1316 (FIG. 13E) on both ends. Connector 1316 on one end of cable 1134 is configured to releasably couple to connector 1310-1 on module pack 1110, and connector 1316 on the other end of cable 1134 is configured to releasably couple to connector 1310-2 on SSCD 1120 (FIG. 13D). Connector 1310-1 includes ports A, B, C, U, V, and W, and two sets of ports N1 through N3.

[0172] Arrays 700-A, 700-B, and 700-C are selectively coupled to motor 101-1 and connector 1310-1 (and SSCD 1120 via cable 1134) via lines 1340-A through 1340-C and lines 1350-A through 1350-C, respectively. Similarly, arrays 700-U, 700-V, and 700-W are selectively coupled to motor 101-2 and connector 1310-1 via lines 1340-U through 1340-W and lines 1350-U through 1350-W, respectively. Each line 1340 and 1350 can include one or more conductors that route energy between its components and can include one or more switches between the components. Each switch shown in Figures 13A-13C may be implemented as any type of switch, for example, a mechanical switch, a relay, a contactor, or a power semiconductor, unless otherwise stated or logically impossible.

[0173] In this embodiment, each array 700-A through 700-W is configured and operative such that system I / O port SIO1 is a phase port and system I / O port SIO2 is a neutral port. The neutral ports SIO2 of arrays 700-A and 700-U are coupled to form a common neutral point N1. Similarly, the neutral ports SIO2 of arrays 700-B and 700-V are coupled to form a common neutral point N2, and the neutral ports SIO2 of arrays 700-C and 700-W are coupled to form a common neutral point N3.

[0174] Phase port SIO1 of array 700-A is selectively coupled to motor 101-1 via system I / O port SIO1 of module pack 1110 and line 1340-A, which includes switches SA1 and SA2. When switches SA1 and SA2 are closed, line 1340-A couples phase port SIO1 of array 700-A to motor 101-1.

[0175] Phase port SIO1 of array 700-A is also selectively coupled to SSCD 1120 via I / O port SIO1 of module pack 1110, a portion of line 1340-A including switch SA2, and a portion of line 1350-A. When switch SA2 is closed, lines 1340-A and 1350-A couple port SIO1 of array 700-A to port A of connector 1310-1, which couples to SSCD 1120 via cable 1134 and connector 1310-2.

[0176] Phase port SIO1 of array 700-B is selectively coupled to motor 101-1 via system I / O port SIO2 of module pack 1110 and line 1340-B, which includes switches SB1 and SB2. When switches SB1 and SB2 are closed, line 1340-B couples phase port SIO1 of array 700-B to motor 101-1.

[0177] Phase port SIO1 of array 700-B is also selectively coupled to SSCD 1120 via I / O port SIO2 of module pack 1110, a portion of line 1340-B including switch SB2, and a portion of line 1350-B. When switch SB2 is closed, lines 1340-B and 1350-B couple port SIO1 of array 700-B to port B of connector 1310-1.

[0178] Phase port SIO1 of array 700-C is selectively coupled to motor 101-1 via system I / O port SIO3 of module pack 1110 and line 1340-C, which includes switches SC1 and SC2. When switches SC1 and SC2 are closed, line 1340-C couples phase port SIO1 of array 700-C to motor 101-1.

[0179] Phase port SIO1 of array 700-C is also selectively coupled to SSCD 1120 via I / O port SIO3 of module pack 1110, a portion of line 1340-C including switch SC2, and a portion of line 1350-C. When switch SC2 is closed, lines 1340-C and 1350-C couple port SIO1 of array 700-C to port C of connector 1310-1.

[0180] Phase port SIO1 of array 700-U is selectively coupled to motor 101-2 via system I / O port SIO4 of module pack 1110 and line 1340-U, which includes switches SU1 and SU2. When switches SU1 and SU2 are closed, line 1340-U couples phase port SIO1 of array 700-U to motor 101-2.

[0181] Phase port SIO1 of array 700-U is also selectively coupled to SSCD 1120 via I / O port SIO4 of module pack 1110, a portion of line 1340-U including switch SU2, and a portion of line 1350-U. When switch SU2 is closed, lines 1340-U and 1350-U couple port SIO1 of array 700-U to port U of connector 1310-1.

[0182] Phase port SIO1 of array 700-V is selectively coupled to motor 101-2 via system I / O port SIO5 of module pack 1110 and line 1340-V, which includes switches SV1 and SV2. When switches SV1 and SV2 are closed, line 1340-V couples phase port SIO1 of array 700-V to motor 101-2.

[0183] Phase port SIO1 of array 700-V is also selectively coupled to SSCD 1120 via I / O port SIO5 of module pack 1110, a portion of line 1340-V including switch SV2, and a portion of line 1350-V. When switch SV2 is closed, lines 1340-V and 1350-V couple port SIO1 of array 700-V to port V of connector 1310-1.

[0184] Phase port SIO1 of array 700-W is selectively coupled to motor 101-2 via system I / O port SIO6 of module pack 1110 and line 1340-W, which includes switches SW1 and SW2. When switches SW1 and SW2 are closed, line 1340-W couples phase port SIO1 of array 700-W to motor 101-2.

[0185] Phase port SIO1 of array 700-W is also selectively coupled to SSCD 1120 via I / O port SIO6 of module pack 1110, a portion of line 1340-W including switch SW2, and a portion of line 1350-W. When switch SW2 is closed, lines 1340-W and 1350-W couple port SIO1 of array 700-W to port W of connector 1310-1.

[0186] In this embodiment, the common neutral points (N1, N2, N3) of each segment of the array are coupled via a bus bar 1320 or other conductor, thereby forming a common neutral point for all three segments and two three-phase converters, one for arrays 700-A through 700-C and one for arrays 700-U through 700-W, that provide AC power to motors 101-1 and 101-2, respectively.

[0187] Additionally, common neutral point N1 of segment AU is selectively coupled to port N1 of connector 1310-1 via system I / O port SIO7 and switch SN1 of module pack 1110. Similarly, common neutral point N2 of segment BV is selectively coupled to port N2 of connector 1310-1 via system I / O port SIO8 and switch SN2 of module pack 1110, and common neutral point N3 of segment CW is selectively coupled to port N3 of connector 1310-1 via system I / O port SIO9 and switch SN3 of module pack 1110.

[0188] System 100 includes a charging port 1330 that couples to charging source 150, which can be an AC charging source (e.g., the utility grid) or a DC charging source. Charging port 1330 includes system I / O ports SIO1 and SIO2 for DC charging, for example, when in a DC charging state and coupled to a DC charging source. Charging port 1330 also includes system I / O ports SIO3 and SIO4 for AC charging, for example, when in an AC charging state and coupled to an AC charging source.

[0189] System I / O ports SIO1 and SIO2 of charging port 1330 are selectively coupled to arrays 700-A through 700-W via lines 1350-C and 1350-W and lines 1340-A through 1340-W. The DC charging source can charge the energy sources 206 of the modules 108 of arrays 700-A through 700-W when switches SCH2, SCH3, SCH5, SCH6, SCH7, SCH8, SA2, SB2, SC2, SU2, SV2, and SW2 are closed. Charging all arrays simultaneously is not required. For example, switches SA2, SB2, SC2, SU2, SV2, and SW2 can be controlled to selectively charge arrays 700-A through 700-W, respectively, when switches SCH2, SCH3, SCH5, SCH6, SCH7, and SCH8 are closed.

[0190] The AC charging source can charge the energy sources 206 of the modules 108 of the arrays 700-A through 700-W when switches SCH1, SCH4 through SCH8, and SA2, SB2, SC2, SU2, SV2, and SW2 are closed. Switches SA2, SB2, SC2, SU2, SV2, and SW2 can also be controlled to selectively charge the arrays 700-A through 700-W, respectively, in an AC charging state when SCH1 and SCH4 through SCH8 are closed. During AC charging, the AC signal from the charging source 150 can be routed to the modules 108 of the module pack 1110 without being converted to DC, for example.

[0191] The charging port 1330 can also be coupled to the SSCD 1120 via lines 1350-A, 1350-C, 1350-U, and 1350-W. For example, in a DC charging state in which the charging port 1330 is coupled to a DC charging source, line 1350-C can couple system I / O port SIO2 of the charging port 1330 to port C of the connector 1310-1, and line 1350-W can couple system I / O port SIO1 of the charging port 1330 to port W of the connector 1310-1. When in an AC charging state, line 1350-A can couple system I / O port SIO4 of the charging port 1330 to port A of the connector 1310-1, and line 1350-U can couple system I / O port SIO3 of the charging port 1330 to port U of the connector 1310-1.

[0192] Inductor L1 is an optional component that can be used to filter the AC signal being used to charge the energy source of module 108 during AC charging. If only DC charging is used, or if the EV includes an on-board charger that converts the AC charging source to DC for charging module 108, inductor L1 can be omitted.

[0193] In this example embodiment, the ports of connector 1310 may be arranged as shown in FIG. 13A. Different arrangements are possible, where port S and port R are shorted together using wire 1312 or other conductor. This allows system 100, e.g., control system 102, to verify that connectors 1310-1 and 1310-2 are properly connected before operating system 100, e.g., before applying power to motors 101-1 and 101-2 and / or load 301, as will be described in more detail with reference to FIG. 13E.

[0194] SSCD controller 1122 and / or control system 102 can be configured to operate switches in system 100 to selectively power motors 101-1 and / or 101-2, power auxiliary loads 301, and / or charge energy sources 206 of modules 108 in module pack 1110, for example, by sending control signals to the switches. Example techniques for controlling system 100 of FIG. 13A are described below with reference to FIGS. 13F-13H.

[0195] 13B, this embodiment of system 100 differs from the embodiment of FIG. 13A because system 100 powers only one motor 101-1 and does not include a bus bar 1320 for coupling the common neutral points of the segments. Instead, each of segments AU, BV, and CW forms a larger array than the individual arrays 700-A through 700-W for powering motor 101-1.

[0196] In this embodiment, arrays 700-A through 700-C are configured and operated such that system I / O port SIO1 is a phase port and system I / O port SIO2 is a neutral port. In contrast, arrays 700-U through 700-W are configured and operated such that system I / O port SIO1 is a neutral port and system I / O port SIO2 is a phase port. In this manner, each of segments AU, BV, and CW forms a large array that outputs a single-phase AC signal.

[0197] Because port SI02 of arrays 700-U through 700-V is a phase port, there is no common neutral point between each segment array. However, points N1, N2, and N3 between segments AU, BV, and CW, respectively, are coupled to connector 1310-1 in the same manner as in the embodiment of FIG. 13A. This allows the AC signals output by arrays 700-U through 700-W to be routed via cable 1134 to SSCD 1120, which also powers auxiliary load(s) 301.

[0198] The similarities and slight differences between the embodiments of system 100 in Figures 13A and 13B allow the module pack 1110 to be manufactured for both applications with only minor differences in the manufacturing process. For example, all manufacturing steps can be the same, with only the addition of bus bars for the two motor applications. This significantly reduces the complexity and costs associated with manufacturing different energy systems and battery packs for different types of EVs.

[0199] Control system 102 can be adapted to operate modules 108 of arrays 700-A through 700-W based on whether module pack 1110 is powering one motor 101-1 or two motors 101-1 and 101-2. Example techniques for controlling system 100 of Figure 13B are described below with reference to Figures 13I through 13K.

[0200] Referring to FIG. 13C, this embodiment of system 100 differs from the embodiment of FIGS. 13A and 13B because it includes switches SB1 and SB2 for selectively coupling the common neutral of the segments. In this manner, control system 102 can control switches SN1 and SN2 based on whether module pack 1110 is mounted or installed as a one-motor EV or a two-motor EV. If the EV has two motors powered by module pack 1110, control system 102 can close switches SB1 and SB2 to form a common neutral for the three segments, similar to busbar 1320. If the EV has one motor powered by module pack 1110, control system 102 can open switches SB1 and SB2 so that there is no common neutral among the three segments.

[0201] 13D is a block diagram of an example embodiment of an SSCD 1120 for powering an auxiliary load 301. The SSCD 1120 of this embodiment can be used, for example, as the SSCD of each of the embodiments shown in FIGS. 13A-13C and described herein.

[0202] SSCD 1120 includes system I / O ports SIO1 to SIO7 for coupling to connector 1310-2, and system I / O ports SIO8 and SIO9 for coupling to DC+ line 1136-1 and DC- line 1136-2, respectively, of DC bus 1136, which routes DC power output by SSCD 1120 to auxiliary load(s) 301.

[0203] In particular, system I / O ports SIO1, SIO2, and SIO3 of SSCD 1220 are coupled to port SIO1 of arrays 700-U, 700-V, and 700-W, respectively, via ports U, V, and W of cable 1134. Similarly, system I / O ports SIO4, SIO5, and SIO6 of SSCD 1220 are coupled to port SIO1 of arrays 700-A, 700-B, and 700-C, respectively, via ports A, B, and C of cable 1134.

[0204] System I / O port SIO7 of SSCD 1220 is coupled to port N of connector 1310-2. Port N of connector 1310-2 can be coupled to port N2 of connector 1310-1 via conductors of cable 1134. In a two-motor embodiment, this couples the common neutral of array segments AU, BV, and CW to intermediate DC line 1363-2 of SSCD 1220 so that the neutral potentials of both module pack 1110 and SSCD 1220 are the same or close to the same (e.g., within a defined tolerance). In a single-motor embodiment, this couples the neutral of arrays 700-U through 700-V to intermediate DC line 1363-2, as described in more detail below.

[0205] The SSCD 1220 can be or include a rectifier circuit including a diode circuit 1360 and a filter circuit 1362. The diode circuit 1360 is configured as two three-phase full-wave rectifiers. The diode circuit 1360 includes diodes D1 through D14. The diode circuit 1360 includes three diode segments DSU, DSV, and DSW that form the three-phase full-wave rectifier. The rectifier circuit 1360 also includes three diode segments DSA, DSB, and DSC to form the three-phase full-wave rectifier. Each diode segment includes two diodes coupled between a DC+ line 1363-1 and a DC- line 1363-3.

[0206] Diodes D1, D3, D5, D7, D9, D11, and D13 allow positive current to flow from their respective ports onto DC+ line 1363-1, generating a positive pulse on DC+ line 1363-1. Similarly, diodes D2, D4, D6, D8, D10, D12, and D14 allow negative current to flow from their respective ports onto DC+ line 1363-1, generating a negative pulse on DC- line 1363-3. Positive pulse diodes D1, D3, D5, D7, D9, D11, and D13 and negative pulse diodes D2, D4, D6, D8, D10, D12, and D14 together form two three-phase full-wave rectifiers.

[0207] Diode circuit 1360 also includes an output diode segment DSO that includes two diodes D13 and D14. A point between diodes D13 and D14 is coupled to intermediate DC line 1363. Diodes D13 and D14 are optional components. If diodes D13 and D14 are not included, system port SIO7 can be coupled to intermediate DC line 1363-2.

[0208] System I / O ports SIO1-SIO3 of SSCD 1120 are coupled between the diodes of diode segments DSU-DSW, respectively, and system I / O ports SIO4-SIO6 of SSCD 1120 are coupled between the diodes of diode segments DSA-DSC, respectively. In a two-motor embodiment, this couples the phase output of array 700-A to diode segment DSA, the phase output of array 700-B to diode segment DSB, the phase output of array 700-C to diode segment DSC, the phase output of array 700-U to diode segment DSU, the phase output of array 700-V to diode segment DSV, and the phase output of array 700-W to diode segment DSW. In a single-motor embodiment, this couples the phase output of array 700-U to diode segment DSA, the phase output of array 700-V to diode segment DSB, and the phase output of array 700-W to diode segment DSC, as described below.

[0209] SSCD 1120 includes a relay 1361 disposed along DC+ line 1363-1 and coupled between diode segments DSU-DSW and diode segments DSA-DSC. As described in more detail below, SSCD controller 1122 can control relay 1361 by sending a control signal to relay 1361 based on, for example, whether system 100 is in a charging or discharging state (e.g., an EV drive mode) and / or whether system 100 is powering one or two motors 101.

[0210] Diode circuit 1360 is coupled to filter circuit 1362 via DC lines 1363-1 to 1363-3. Filter circuit 1362 is coupled to inductor L on DC+ line 1363-1. u and the inductor L on the DC-line 1363-3 l The filter circuit 1362 also includes a resistor R coupled between the DC+ line 1363-1 and the intermediate DC line 1363-2. uand a resistor R coupled between the intermediate DC line 1363-2 and the DC- line 1363-3. l Similarly, the filter circuit 1362 includes a capacitor C coupled between the DC+ line 1363-1 and the intermediate DC line 1363-2. u and a capacitor C coupled between the intermediate DC line 1363-2 and the DC- line 1363-3. l Includes:

[0211] The diode circuit 1360 is configured to convert the three-phase AC signal into voltage pulses of the same polarity, e.g., positive polarity, between the DC+ line 1363-1 and the intermediate DC line 1363-2, and voltage pulses of the same polarity, e.g., positive polarity, between the intermediate DC line 1363-2 and the DC- line 1363-3. u and R l , capacitor C u and C l , and inductor L u and L i is configured to filter these pulses to produce a constant or near-constant DC output signal between the DC+ line 1136-1 and the DC- line 1136-3 of the DC bus 136. u and C l can also operate as an energy buffer, similar to energy buffer 204, to attenuate or filter fluctuations in current between DC+ line 1136-1 and DC- line 1136-3.

[0212] As will be explained in more detail below, the SSCD controller 1122 controls the capacitor C u The voltage level V c,u and capacitor C l The voltage level V c,l can be adjusted to provide a target output DC voltage level between DC+ line 1136-1 and DC- line 1136-3. This output voltage is determined by the capacitance of capacitor C u The voltage level V c,u and capacitor C l The voltage level Vc,l The SSCD controller 1122 controls the voltage level V c,u and V c.l can be adjusted to be at or close to the same level, or to have different voltage levels.

[0213] The SSCD1120 uses a capacitor C u The voltage level V c,u , capacitor C l The voltage level V c,l , output current I out , inductor L u The current I passing through L,u , and inductor L i The current I passing through L,l The SSCD controller 1122 may include a sensor that senses a voltage or current. The sensors may include a voltage sensor and a current sensor. The outputs of the sensors may be communicatively coupled to the SSCD controller 1122, for example, using a communication path or link 1132. For example, the communication path or link 1132 may be communicatively coupled to each sensor and relay 1361 using one or more conductors for each component.

[0214] 13D, the SSCD 1120 can include a local controller 1368 that collects sensed signals and provides the sensed signals to the SSCD controller 1122 via communication path or link 1132. The SSCD local controller 1368 can also control the relay 1361 based on control signals received from the SSCD controller 1122 via communication path or link 1132.

[0215] SSCD 1120 includes a discharge circuit 1364 coupled to DC lines 1363-1 through 1363-3. Discharge circuit 1364 discharges capacitor C u and C lThe module pack 1110 may include a disconnect feature, such as a contactor, that can open to disconnect the module pack 1110 and its components upon detection of a condition. This allows the capacitor C u and C l However, the capacitor C u and C l to The stored energy must also be safely discharged. The discharge circuit 1364 safely discharges the capacitor C without sending energy to the load(s) 301 via the DC bus 1136 or the module pack 1110. u and C l can be discharged.

[0216] 13E is a diagram illustrating an example embodiment of a connector 1310 for coupling a module pack 1110 and an SSCD 1120. Whether the EV is a one-motor EV or a two-motor EV, the port of connector 1310-1 of module pack 1110 that mates with the port of connector 1316-1 at the end of cable 1134 can be positioned in the same way. The port of connector 1310-2 of SSCD 1120 that mates with the port of connector 1316-2 at the other end of cable 1134 can be positioned in the same way, except that connector 1316-2 may be rotated 90 degrees (e.g., counterclockwise) when coupled to connector 1310-2 of SSCD 1120 of a one-motor EV relative to its connection in a two-motor EV.

[0217] In either embodiment, ports with the same identifier and located in the same position in connectors 1316-1 and 1316-2 are coupled to each other by conductors of cable 1134. For example, in each embodiment, port C of connector 1316-1 is coupled to port C of connector 1316-2.

[0218] In module pack 1110, when connector 1316-1 is properly connected to connector 1310-1, ports in connectors 1310-1 and 1316-1 that have the same identifier and are located in the same position are coupled. For example, when port C of connector 1316-1 is connected to port C of connector 1310-1, connector 1316-1 is properly connected to connector 1310-1.

[0219] In SSCD 1120, the orientation of the ports of connector 1316-2 can differ between single-motor and two-motor embodiments. For a two-motor embodiment, ports A, B, and C of connector 1316-2 are coupled to ports A, B, and C, respectively, of connector 1310-2, ports U, V, and W of connector 1316-1 are coupled to ports U, V, and W, respectively, of connector 1310-2, a first set 1313-1 of ports N1-N3 of connector 1316-2 is coupled to a set 1314 of no-connect (NC) ports of connector 1310-2, a second set of ports N1-N3 is coupled to a set 1315 of ports including two NC ports and an N port, and port N2 is coupled to an N port.

[0220] 13D, phase ports SIO1 of arrays 700-U, 700-V, and 700-W of connector 1310-2 are coupled to system I / O ports SIO1, SIO2, and SIO3 of SSCD 1120. In this two-motor configuration, phase ports SIO1 of arrays 700-U, 700-V, and 700-W of module pack 1120 are coupled between two diodes of diode segments DSU, DSV, and DSW, respectively, when connector 1316-2 is properly coupled to connector 1310-2. Similarly, when connector 1316-2 is properly coupled to connector 1310-2, phase ports SIO1 of arrays 700-A, 700-B, and 700-C of connector 1310-2 are coupled to system I / O ports SIO4, SIO5, and SIO6 of SSCD 1120, and phase ports SIO1 of arrays 700-A, 700-B, and 700-C of module pack 1120 are coupled between two diodes of diode segments DSA, DSB, and DSC, respectively.

[0221] 13A, system I / O ports SIO7, SIO8, and SIO9 of module pack 1110 can be coupled to both a first set 1313-1 of ports N1-N3 and a second set of ports N1-N3 of connector 1310-1 shown in FIG. 13E. In this manner, common neutral N2 of segment 70BV can be coupled to connector N of connector 1310-2 when both connectors 1316-1 and 1316-2 are properly coupled to connectors 1310-1 and 1310-2, respectively. This connection routes the common neutrals of segments AU, BV, and CW to intermediate DC line 1363-2 of SSCD 1120 such that port N of connector 1310-2 is coupled to system I / O port SIO7, which is coupled to intermediate DC line 1363-2.

[0222] In the single-motor embodiment, connector 1316-2 is rotated 90 degrees relative to connector 1316-2 in the two-motor embodiment. The ports of connector 1310-2 are coupled to system I / O ports SIO1-SIO7 of SSCD 110, just as in the two-motor embodiment (e.g., port U of connector 1310-2 coupled to SIO1, port V of connector 1310-2 coupled to SIO2, etc.). Here, due to the rotation of connector 1316-2, ports A, B, and C of connector 1316-2 are coupled to ports U, V, and W of connector 1310-2, respectively. This results in the phase outputs of arrays 700-A, 700-B, and 700-C being routed to diode segments DSU, DSV, and DSW, respectively, of SSCD 1120 when relay 1361 is closed. However, relay 1361 is held open in single-motor control.

[0223] Ports U, V, and W of connector 1316-2 are coupled to a set of ports 1315 including the two N, C, and N ports of connector 1310-2, such that port V is coupled to the N port of connector 1310-2. As shown in FIG. 13G and described below, system I / O ports SIO1 of arrays 700-U through 700-W, which are the neutral ports in the single-motor embodiment, can be coupled to form a common neutral. In this example, this common neutral is routed to intermediate DC line 1363-2 by coupling port V of connector 1310-1 to port V of connector 1316-1, port V of connector 1316-1 to port V of connector 1316-2, port V of connector 1316-2 to port N of connector 1310-2, and port N of connector 1310-2 to intermediate DC line 1363-2 via system I / O port SIO7 of SSCD 1120.

[0224] A first set 1313-1 of ports N1 through N3 of connector 1316-2 are coupled to ports A through C, respectively. In this manner, system I / O port SIO2 of arrays 700-U, 700-V, and 700-W, which are counterpart ports of arrays 700-U, 700-V, and 700-W in this embodiment, are coupled to diode segments DSA, DSB, and DSC, respectively, when connectors 1316-1 and 1316-2 are appropriately coupled to connectors 1310-1 and 1310-2, respectively. For example, port SIO2 of array 700-2 is coupled to both N1 ports of connector 1310-1, and each port N1 of connector 1310-1 is coupled to a corresponding port N1 of connector 1316-1, which in turn is coupled to a corresponding port N1 of connector 1316-2. Port N1 of the first set 1313-1 of connectors 1316-2 is coupled to port A of connector 1310-2, which is coupled to diode segment DSA via system I / O port SIO4 of SSCD 1120.

[0225] This allows the physical arrangement of connector 1310-2, cable 1134, and the ports of SSCD 1120 that couple to the ports of connectors 1310-1 and 1310-2 to be the same for both one-motor and two-motor applications. Cable 1134 can simply be rotated 90 degrees for single-motor control relative to the two-motor control arrangement, routing the phase outputs of arrays 700-U through 700-V to rectifier circuit 1360 of SSCD 1120 at ports SIO4 through SIO6 of SSCD 1120 where the phase outputs of arrays 700-A through 700-C are routed during two-motor control. Port NC of connector 1310-2 is not connected to any components of SSCD 1120.

[0226] Ports S and R of connector 1310-1 can be shorted with wire 1312 or other conductor to allow SSCD controller 1122 to sense whether connector 1310-2 is properly connected based on whether system 100 is being used to power one motor or two motors. Port S is the transmit port, and port R is the receive port. SSCD controller 1122 can send a signal on port S and detect whether the signal is received on port R. In a two-motor embodiment, if connectors 1316-1 and 1316-2 are properly coupled to connectors 1310-1 and 1310-2, respectively, SSCD controller 1122 should be able to detect the signal. When SSCD controller 1122 is configured for two-motor control, if a signal is applied to port S and not detected at port R, this indicates a misconnection and SSCD controller 1122 can prevent operation of SSCD 1120 and / or module pack 1110. For example, the SSCD controller 1122 may send a control signal to the MCD 112 of the control system 102 indicating a misconnection, which may result in the MCD 112 not discharging energy from the modules 108 of the module pack 1110.

[0227] In a single motor embodiment, if connectors 1316-1 and 1316-2 are properly coupled to connectors 1310-1 and 1310-2, respectively, the SSCD controller 1122 should not be able to detect a signal. When the SSCD controller 1122 is configured for single motor control, if a signal is applied to port S and detected at port R, this indicates a misconnection and the SSCD controller 1122 can prevent operation of the SSCD 1120 and / or module pack 1110.

[0228] In some embodiments, ports S and R can be shorted at connector 1310-2 instead of connector 1310-1. In this example, MCD 112 of control system 102 can send a test signal on port S and determine whether a signal is received on port R. MCD 112 can then enable or disable operation of module pack 1110 and / or SSCD 1120 in a manner similar to SSCD controller 1122.

[0229] 13F-13H illustrate example techniques for controlling components of the example embodiment of system 100 shown in FIG. 13B (or FIG. 13C) and FIG. 13D to supply and regulate AC power to a single motor 101-1 of an EV and to supply and regulate DC power to auxiliary load(s) 301.

[0230] FIG. 13F is a diagram showing an example of an equivalent rectifier circuit 1380 when controlling a single motor, and FIG. 13G is a diagram showing an example of the configuration of an equivalent module pack 1381 when controlling a single motor.

[0231] When operating motor 101-1, SSCD controller 1122 can open relay 1361, thereby preventing the phase outputs of arrays 700-A, 700-B, and 700-C present at system IO ports SIO1-SIO3 from passing through relay 1361 to DC+ line 1363-1 and DC- line 1363-3 of SSCD 1120. Thus, diode segments DSU-DSW are effectively isolated from the other diode segments DSA-DSC and DSO.

[0232] Control system 102 can close switches SA1, SA2, SB1, SB2, SC1, and SC2 to couple the phase outputs of arrays 700-A through 700-C to motor 101-1. Control system 102 can also open switches SCH1 through SCH4 to isolate charging source 150 from the components of system 100. Control system 102 can also close switches SN1 through SN3 to couple the phase outputs of arrays 700-U through 700-W at their ports SIO2 to ports N1, N2, and N3 of connector 1310-1, respectively, via cable 1134 and by rotation of connector 1316-2 to diode arrays DSA, DSB, and DSC, as described above.

[0233] Control system 102 can close switches SU2, SV2, SW2, SCH5, and SCH6 to combine the neutrals of arrays 700-U, 700-V, and 700-W to form a common neutral, which also routes the neutrals of arrays 700-U through 700-W to ports U, V, and W, respectively, of connector 1310-1, which, as described above, route these common neutrals to intermediate bus 1363-2 via cable 1134 and by rotation of connector 1316-2.

[0234] When the embodiment of system 100 of Figure 13C is used, control system 102 opens switches SN1 and SN2 to remove the equivalent bus bar that would otherwise connect the common neutrals, and also opens switches SU1, SV1, and SW1 because there are no motors connected on the other side of these switches, which can also be left open in the embodiment of system 100 of Figure 13B.

[0235] In the illustrated configuration of FIG. 13F, the phase outputs of arrays 700-U through 700-W charge capacitors during operation of motor 101-1. Diodes D7 through D12 rectify the AC signals received from arrays 700-U through 700-W and pass the rectified signals to filter circuit 1362, which filters the rectified signals into DC signals that are output on DC power bus 1136. Thus, arrays 700-U through 700-W can supply power to auxiliary load(s) 301 via SSCD 1120, and arrays 700-A through 700-C can supply AC power to motor 101-1. Arrays 700-U through 700-W are coupled to arrays 700-A through 700-C, respectively, and also contribute to the AC signals output to motor 101-1.

[0236] Figure 13H is a diagram of an example control scheme for single motor control using system 100 of Figure 13B or 13C. In this example scheme, external motor controller 104 is configured to provide control information to SSCD controller 1122 via communication path or link 1135, as described in more detail below. This control information may be referred to as external control information and may include modulation indexes for each phase of the AC signal supplied to motor 101-1, modulated reference signals for each phase, modulation indexes and reference signals for each phase, or other control information.

[0237] Each segment of the array (e.g., segments AU, BV, and CW) can output a single-phase AC signal that includes a superposition of the output voltages from the modules of the array within the segment. For single motor control, the external control information for a phase can be the information of the segment (e.g., the segment with the corresponding phase angle) that outputs the AC signal for that phase.

[0238] The motor controller 104 can generate external control information based on a reference signal for motor control, a motor feedback signal received from the motor 101-1 via communication path or link 1391, and / or a module feedback signal received from the control system 102 of the module pack 1110 via communication path or link 1133. The motor feedback signal can include, for example, an operating characteristic of the motor 101-1, such as the actual or estimated instantaneous torque of the motor 101-1 and / or the speed of the motor 101-1. The module feedback signal can include, for example, an output voltage level of the AC signal supplied to the motor 101-1 by the module pack 1110 and / or an output current level of the AC signal supplied to the motor 101-1 by the module pack 1110. The motor controller 104 can provide the external control information to the SSCD controller 1122 via communication path or link 1135.

[0239] The SSCD controller 1122 is configured to process external control information and generate processed control information based on a reference signal of the SSCD 1120 (e.g., a reference value for the output DC signal) and / or an SSCD feedback signal received from the SSCD 1120 via a communication path or link 1132. The processed control information may include a modulation index for each phase or a modulated reference signal for each phase. The SSCD feedback signal may include, for example, a sensed voltage and / or current of the SSCD 1120. For example, the SSCD feedback signal may be a signal representing a voltage across a capacitor C u The voltage level V c,u , capacitor C l The voltage level V c,l , inductor L u The current I passing through L,u , and / or inductor L i The current I passing through L,l may include:

[0240] Processing the control information may include adjusting the control information, e.g., adjusting a modulation index for one or more phases and / or a modulation reference signal for one or more phases. Generally, the SSCD controller 1122 may adjust the control information to adjust the DC signal output by the SSCD 1120 to the auxiliary load(s) 301. For example, the SSCD controller 1122 may adjust the control information to adjust the voltage level and / or current level of the DC signal output to the DC power bus 1136.

[0241] To adjust the voltage level of the output DC signal, the SSCD controller 1122 adjusts the capacitance of the capacitor C so that the voltage level of the output DC signal is the sum of these voltage levels. u The voltage level V c,u and / or capacitor C l The voltage level V c,l In some embodiments, the SSCD controller 1122 can adjust the voltage level V c,u and V c.l The present invention can be configured to balance the above.

[0242] The SSCD controller 1122 adjusts the external control information to c,u and V c.l Adjust the capacitor C from the module pack 1110. u and C l For example, if the voltage level of the output DC signal is lower than the reference voltage of the output DC signal, the SSCD controller 1122 may adjust the external control information to transfer energy from the module pack 1110 to the capacitor C u and C l If the voltage level of the output DC signal is greater than the reference voltage of the output DC signal, the SSCD controller 1122 adjusts the external control information to transfer the current from the module pack 1110 to the capacitor C u and C l This can reduce the amount of energy being transferred to the

[0243] The SSCD controller 1122 adjusts the external control information to transfer the capacitor C u and C l By increasing or decreasing the amount of energy transferred to the voltage level V c,u and V c.l For example, the SSCD controller 1122 can compare a reference voltage for each capacitor (which may be, for example, half the reference voltage for the output DC signal) to the sensed value for the capacitor. One or both of these comparisons, and / or the reference voltage for the output DC signal and V c,u and V c.l Using these comparisons, SSCD controller 1122 removes capacitor C from module pack 1110. u and C l It can be determined whether to increase or decrease the amount of energy being transferred to the

[0244] The SSCD controller 1122 adjusts the external control information to drive the capacitor C u and C l If SSCD controller 122 determines to increase or decrease the amount of energy being transferred to motor 101-1, it can adjust the modulation index and / or modulated reference signal in the same manner for all three phases, for example, by increasing or decreasing their values ​​by the same amount. In this way, the adjustments do not affect the amount of AC power delivered to motor 101-1. That is, adjusting the common-mode voltage of the AC signal delivered to motor 101-1 can adjust the voltage level of the output DC signal.

[0245] In this example embodiment, arrays 700-U to 700-W are connected to capacitors C u and C l Capacitor C supplies energy to u and C lTo increase or decrease the amount of energy being transferred to the modules 108, the SSCD controller 1122 can adjust the modulation indexes for the three phases and provide the adjusted modulation indexes to the control system 102 for use in controlling the modules 108 of the arrays 700-U through 700-W. The same adjusted modulation indexes can also be provided to the corresponding arrays 700-A through 700-C. For example, the modulation index for the first phase can be provided to both arrays 700-A and 700-U, the modulation index for the second phase can be provided to both arrays 700-B and 700-V, and the modulation index for the third phase can be provided to both arrays 700-C and 700-W.

[0246] The SSCD controller 1122 provides the processed control information to the control system 102 of the module pack 1110. As described above, the control system 102 may include one or more MCDs 112, LCDs 114, and an array controller 900 for each array 700, or a controller 950 for multiple arrays 700, e.g., a controller 950 for all arrays 700 in the module pack 1110, or a controller 950 for each segment. In this embodiment, the control system 102 may include an array controller 900 for each array 700-A through 700-W.

[0247] An array controller 900 for an array 700 can perform intra-phase balancing techniques to balance one or more operating characteristics of the modules 108 in the array 700. The controller 900 for an array 700 can receive processed control information for that array 700 (e.g., a processed modulation index for that array 700) and generate a modulation index for each module 108 of the array 700, as described herein, based on the processed control information and one or more operating characteristics of each module in the array 700. For example, the controller 900 for array 700-A can receive the processed modulation index for array 700-A and adjust the processed modulation index for each module 108 in array 700-A to balance one or more operating characteristics of the modules 108 in the array 700-A.

[0248] As described herein, MCD 112 can provide modulation indices and reference signals, or modulated reference signals, for modules 108 of array 700 to LCD 114, which controls modules 108, to generate the AC signals output by array 700. Here, in the single-motor embodiment of FIG. 13H, the AC signals generated by arrays 700-A through 700-W are supplied to motor 101-1.

[0249] Furthermore, the AC signals generated by arrays 700-U to 700-W are supplied to SSCD 1120 by cable 1134. SSCD 1120 converts the AC signals to DC signals and outputs the DC signals to DC power bus 1136 to power auxiliary load 301.

[0250] 13I-13K illustrate example techniques for controlling components of the example embodiment of system 100 shown in FIGS. 13A (or 13C) and 13D to supply and regulate AC power to two motors 101-1 and 101-2 of an EV and to supply and regulate DC power to auxiliary load(s) 301.

[0251] Fig. 13I is a diagram showing an example of an equivalent rectifier circuit 1382 when two motors are controlled. Fig. 13J is a diagram showing an example of an equivalent module pack configuration 1383 when two motors are controlled.

[0252] To operate motors 101-1 and 101-2, SSCD controller 1122 can close relay 1361, causing the phase outputs of arrays 700-U, 700-V, and 700-W to pass through relay 1361 and reach DC+ line 1363-1 and DC- line 1363-3 of SSCD 1120.

[0253] Control system 102 can close switches SA1, SA2, SB1, SB2, SC1, and SC2 to couple the phase outputs of arrays 700-A, 700-B, and 700-C to motor 101-1. Control system 102 can also close switches SU1, SU2, SV1, SV2, SW1, and SW2 to couple the phase outputs of arrays 700-U, 700-V, and 700-W to motor 101-2. In this example embodiment, arrays 700-U through 700-W are configured and operated such that system I / O port SIO1 of each array 700-U through 700-W is a phase port and system I / O port SIO2 of each array 700-U through 700-W is a neutral port.

[0254] The control system 102 can also open switches SCH1-SCH4 to isolate the charging source 150 from the components of the system 100. The control system 102 can also close switches SN1-SN3 to couple the common neutrals N1-N3 of the array 700 of module packs 1110 to connector 1310-1 and to intermediate DC line 1363-2 by cable 1134. If the embodiment of system 100 of FIG. 13C is used, the control system 102 can close switches SB1 and SB2 to apply an equivalent bus bar coupling the common neutrals of segments AU, BV, and CW.

[0255] Figure 13K is a diagram of an example control scheme for two motor control using system 100 of Figure 13A or 13C. In this example scheme, there is an external motor controller 104-1 for motor 101-1 and an external motor controller 104-2 for motor 101-2. In other examples, one motor controller can be used to control both motors 101-1 and 101-2.

[0256] External motor controller 104-1 is configured to provide external control information to SSCD controller 1122 via communication path or link 1135-1. The external control information may include a modulation index for each phase of the AC signal supplied to motor 101-1, a modulated reference signal for each phase, a modulation index and reference signal for each phase, or other control information. Because motor 101-1 is powered by arrays 700-A through 700-C, the external control information may include control information for arrays 700-A through 700-C, which may also be referred to as subpacks A, B, C, and W. Similarly, external motor controller 104-2 may provide external control information for arrays 700-U through 700-W, which may also be referred to as subpacks U, V, and W, to SSCD controller 1122 via communication path or link 1135-2.

[0257] Motor controller 104-1 may generate external control information for arrays 700-A through 700-C based on a reference signal for motor control, motor feedback signals received from motor 101-1 via communication path or link 1394, and / or module feedback signals received from control system 102 of module pack 1110 via communication path or link 1396. The motor feedback signals may include operating characteristics of motor 101-1, such as, for example, actual or estimated instantaneous values ​​of torque of motor 101-1 and / or speed of motor 101-1. The module feedback signals may include, for example, output voltage levels of AC signals supplied by arrays 700-A through 700-C to motor 101-1 and / or output current levels of AC signals supplied by arrays 700-A through 700-C to motor 101-1.

[0258] Similarly, motor controller 104-2 may generate external control information for arrays 700-U through 700-W based on a reference signal for motor control, motor feedback signals received from motor 101-1 via communication path or link 1395, and / or module feedback signals received from control system 102 of module pack 1110 via communication path or link 1397. The motor feedback signals may include, for example, operating characteristics of motor 101-1. The module feedback signals may include, for example, output voltage levels of AC signals supplied by arrays 700-U through 700-W to motor 101-1 and / or output current levels of AC signals supplied by arrays 700-U through 700-W to motor 101-1.

[0259] Motor controller 104-1 can provide external control information to SSCD controller 1122 via communication path or link 1135-1. Motor controller 104-2 can provide external control information to SSCD controller 1122 via communication path or link 1135-2.

[0260] SSCD controller 1122 is configured to process external control information from each motor controller 104-1 and 104-2 and generate processed control information for subpacks ABC and UVW based on a voltage reference value of SSCD 1120 (e.g., a reference value for the output DC signal), an SSCD feedback signal received from SSCD 1120 via communication path or link 1132, and / or a module feedback signal received from control system 102 of module pack 1110 via communication path or link 1133. The processed control information for subpack ABC or UVW may include a modulation index for each phase of that subpack ABC or UVW or a modulated reference signal for each phase of that subpack ABC or UVW. Thus, the processed control information for subpack ABC or UVW may include a modulation index or a modulated reference signal for each array 700 of subpacks ABC or UVW.

[0261] The SSCD feedback signal may include, for example, the sensed voltage and / or current of the SSCD 1120. For example, the SSCD feedback signal may include the sensed voltage and / or current of the capacitor C u The voltage level V c,u , capacitor C l The voltage level V c,l , inductor L u The current I passing through L,u , and / or inductor L i The current I passing through L,l may include:

[0262] In this example embodiment, the module feedback signal may be, for example, one or more operating characteristics of subpacks A, B, C (OC ABC ) and one or more operating characteristics of the subpack UVW (OC in Figure 13K) UVW The operating characteristics may include, for example, a sum of SOC, SOH, temperature, voltage, current, SOP, and / or SOE for each subpack ABC and UVW.

[0263] Processing the control information may include adjusting the control information, e.g., adjusting a modulation index for one or more phases and / or a modulation reference signal for one or more phases. The SSCD controller 1122 may adjust the control information to adjust the DC signal output by the SSCD 1120 to the auxiliary load(s) 301. For example, the SSCD controller 1122 may adjust the control information to adjust the voltage level and / or current level of the DC signal output to the DC power bus 1136.

[0264] To adjust the voltage level of the output DC signal, the SSCD controller 1122 adjusts the capacitor C so that the voltage level of the DC signal is the sum of these voltage levels. u The voltage level V c,u and capacitor C l The voltage level V c,l In some embodiments, the SSCD controller 1122 can adjust the voltage level V c,u and V c.l The present invention can be configured to balance the above.

[0265] The SSCD controller 1122 adjusts the external control information for one or both of the subpacks ABC and UVW to V c,u and V c.l Adjust the capacitor C from the module pack 1110. u and C l For example, if the voltage level of the output DC signal is lower than the reference voltage of the output DC signal, the SSCD controller 1122 adjusts the external control information for subpacks A, B, C, and U, V, and W to transfer energy from module pack 1110 to capacitor C. u and C l If the voltage level of the output DC signal is lower than the reference voltage of the output DC signal, the SSCD controller 1122 adjusts the external control information for subpacks A, B, C, and U, V, and W to transfer the energy from the module pack 1110 to the capacitor C.u and C l This can reduce the amount of energy being transferred to the

[0266] The SSCD controller 1122 adjusts the external control information for one or both of the subpacks ABC and UVW to set the voltage level V c,u and V c.l Balance the capacitor C from the module pack 1110. u and C l For example, the SSCD controller 1122 may compare a reference voltage for each capacitor (e.g., half the reference voltage for the output DC signal) to the sensed value for the capacitor. One or both of these comparisons, and / or the reference voltage for the output DC signal and V c,u and V c.l Based on a comparison of the sensed values ​​of the capacitors C u and C l The amount of energy being transferred to the target can be increased, decreased, or not adjusted.

[0267] The SSCD controller 1122 adjusts the external control information for one or both of the subpacks ABC and UVW to control the capacitor C u and C l If SSCD controller 122 determines to increase or decrease the amount of energy being transferred to motor 101-1 and / or motor 101-2, SSCD controller 122 may adjust the modulation index and / or modulated reference signal in the same manner for all three phases of the subpack(s), for example, by increasing or decreasing the value by the same amount. In this way, the adjustment does not affect the amount of AC power delivered to motor 101-1 and / or motor 101-2.

[0268] Processing the external control information may also include adjusting the external control information to balance one or more operating characteristics of the module 108, the array 700, and / or groups of arrays. In this example, arrays 700-A, 700-B, and 700-C of subpack ABC and / or arrays 700-U, 700-V, and 700-W of subpacks U-V-W may be configured to operate in a manner similar to that described above, with capacitors C u and C lに The SSCD controller 1122 uses a capacitor C u and C l Subpack balancing techniques can be implemented to balance one or more operating characteristics of subpacks by selecting subpacks that provide additional or less energy to the subpacks. Balancing between subpacks A, B, C, and U, V, and W can be referred to as multiphase subpack balancing.

[0269] For example, if the combined SOC of sub-packs U, V, and W is higher than the combined SOC of sub-packs A, B, and C u and / or C l If more energy is needed, the SSCD controller 1122 switches the subpack U V W to the capacitor C u and C l The external control information for sub-packs U, V, and W can be adjusted to supply more energy to the modules 108. SSCD controller 1122 can adjust the control information, for example, by increasing the modulation index for arrays 700-U through 700-W. In this way, more energy is used from modules 108 in sub-packs U, V, and W than in sub-packs A, B, and C, resulting in a combined SOC that moves toward a balanced state for sub-packs A, B, and C.

[0270] In another example, if the sum of the temperatures of sub-packs A, B, C, and D is greater than the sum of the temperatures of sub-packs U, V, and W, the capacitor C u and / or C l If less energy is required, the SSCD controller 1122 may select the subpack ABC to be connected to the capacitor Cu and C l The external control information for subpacks ABC can be adjusted to supply less energy to arrays 700-A through 700-C. SSCD controller 1122 can adjust the control information, for example, by decreasing the modulation index for arrays 700-A through 700-C. In this way, less energy is used from modules 108 of subpacks ABC, which should decrease the temperatures of modules 108 of subpacks ABC, resulting in a combined temperature trend toward a balanced state for subpacks ABC and UVW.

[0271] Although these examples illustrate adjusting the control information for one subpack at a time, SSCD controller 1122 can adjust the control information for both subpacks ABC and UVW to balance one or more operating characteristics of subpacks ABC and UVW. For example, if the combined SOC of subpacks UVW is higher than the combined SOC of subpacks ABC, SSCD controller 1122 may adjust the control information for subpacks UVW to balance one or more operating characteristics of subpacks ABC and UVW. u and C l The external control information for sub-packs UVW can be adjusted to provide more energy to the capacitor C. u and C l The external control information for the subpack ABC can be adjusted to provide less energy to the SSCD 1120. The SSCD controller 1122 determines whether sufficient energy is available in the capacitor C to adjust the output DC signal of the SSCD 1120. u and C l The device can be configured to perform these adjustments while reliably moving the device.

[0272] The SSCD controller 1122 can perform subpack balancing techniques at any time (e.g., continuously or periodically) while the motors 101-1 and 101-2 are operating and while powering the auxiliary load(s) 301. For example, even when the output DC signal of the SSCD 1120 is regulated to a reference voltage, the SSCD controller 1120 can adjust control information for one or both of the subpacks ABC and UVW to balance one or more operating characteristics of the subpacks ABC and UVW. In a particular example, if the combined SOC of the subpacks ABC is lower than the combined SOC of the subpacks UVW, the SSCD controller 1122 can increase the modulation index for the subpacks UVW and decrease the modulation index for the subpack ABC to balance the combined SOC. In this example, the SSCD controller 1122 can adjust the modulation index so that the energy delivered to the SSCD 1120 is the same and / or so that the output DC signal of the SSCD 1120 remains regulated under other conditions.

[0273] The SSCD controller 1122 provides the processed control information to the control system 102 of the module pack 1110. As described above, the control system 102 may include one or more MCDs 112, LCDs 114, and an array controller 900 for each array 700, or a controller 950 for multiple arrays 700, e.g., a controller 950 for all arrays 700 in the module pack 1110, or a controller 950 for each segment. In this embodiment, the control system 102 may include an array controller 900 for each array 700-A through 700-W.

[0274] An array controller 900 for an array 700 can perform intra-phase balancing techniques to balance one or more operating characteristics of the modules 108 in the array 700. The controller 900 for an array 700 can receive processed control information for that array 700 (e.g., a processed modulation index for that array 700) and generate a modulation index for each module 108 of the array 700, as described herein, based on the processed control information and one or more operating characteristics of each module in the array 700. For example, the controller 900 for array 700-A can receive the processed modulation index for array 700-A and adjust the processed modulation index for each module 108 in array 700-A to balance one or more operating characteristics of the modules 108 in the array 700-A.

[0275] As described herein, MCD 112 can provide modulation indices and reference signals, or modulated reference signals, for modules 108 of array 700 to LCD 114, which controls modules 108 to generate the AC signals output by array 700, where the AC signals generated by arrays 700-A through 700-C are supplied to motor 101-1 and the AC signals generated by arrays 700-U through 700-W are supplied to motor 101-2.

[0276] Additionally, the AC signals generated by arrays 700-A through 700-C and / or the AC signals generated by arrays 700-U through 700-W are supplied to SSCD 1120 via cable 1134. SSCD 1120 converts the AC signals to DC signals and outputs the DC signals to DC power bus 1136 to power auxiliary load 301.

[0277] The control system 102 and / or SSCD controller 1122 can be configured to control charging of the energy sources 206 of the modules 108 of the module pack 1110 while supplying DC power to the auxiliary load(s) 301 in both single-motor and two-motor embodiments.

[0278] 13L-13M illustrate example techniques for controlling components of the example embodiment of system 100 shown in FIG. 13B (or FIG. 13C) and FIG. 13D for charging energy source 206 in a single motor embodiment. FIG. 13L illustrates an example of an equivalent rectifier circuit 1384 during charging in a single motor embodiment. FIG. 13M illustrates an example of an equivalent module pack configuration 1385 during charging in a single motor embodiment.

[0279] To charge the energy sources 206 of the arrays 700 of module packs 1110, the control system 102 can couple the charging source 150 to the arrays 700-A through 700-W of module packs 1110 and route the charging signal to the energy sources 206 of the arrays 700-A through 700-W. To do so, the control system 102 can open switches SA1, SB1, and SC1 to disconnect the module packs 1110 and charging source 150 from the motor 101-1. The control system 102 or the SSCD controller 1122 can also open switches SU1, SV1, and SW1.

[0280] Control system 102 can close switches SA2, SB2, SC2, SU2, SV2, and SW2 to allow a charging signal to reach arrays 700-A through 700-W from charging source 150. Control system 102 can also close switches SN1 through SN3 to couple common neutral points N1 through N3 to SSCD 1120. When DC charging is performed using DC charging source 150, control system 102 or SSCD controller 1122 can close switches SCH2, SCH3, and SCH5 through SCH8 to couple DC charging source 150 to arrays 700-A through 700-W and SSCD 1120 via cable 1134 and ports A through C and U through W of connector 1310-1. For AC charging using AC charging source 150, control system 102 can close switches SCH1 and SCH4 to couple AC charging source 150 to arrays 700-A through 700-W and SSCD 1120 via cable 1134 and ports A and U of connector 1310-1. For AC charging, modules 108 of arrays 700-A through 700-W are connected to AC charging source 150 without an intermediate AC-DC converter (e.g., without an on-board charger). DC charging can be performed using an AC-DC converter coupled between AC charging source 150 and arrays 700-A through 700-W or using DC charging source 150.

[0281] SSCD controller 1122 may also close relay 1361. For DC charging, this switch configuration results in an equivalent rectifier circuit 1384 and equivalent module pack configuration 1385 in which DC charging signals are provided to arrays 700-A through 700-W and diode segments DSU through DSW and DSA through DSC. A positive DC charging signal may be provided to arrays 700-A through 700-C, and a negative DC charging signal may be provided to arrays 700-U through 700-W.

[0282] As noted above, connector 1310-2 can be rotated 90 degrees in single-motor embodiments. This results in the DC charging signals at ports A through C of connector 1310-1 being routed to diode segments DSY through DSW instead of diode segments DSA through DSC. Similarly, this results in ports N1 through N3 of connector 1310-1 coupling points between each of segments A-U, B-V, and C-W to diode segments DSA through DSC, and coupling the DC charging signals at ports U through W to intermediate DC line 1363-2.

[0283] During charging, the SSCD controller 1122 can be bypassed because the DC voltage naturally consists of the DC charging signal coupled to the SSCD 1120. A positive DC charging signal is sent through ports A through C of connector 1310-1 to diode segments D through DW, and a negative DC charging signal is sent through ports U through W of the connector to intermediate DC line 1363-2, resulting in a DC charging signal across capacitor C. u The DC charging signal is applied to the capacitor C u to the voltage level of the charging source 150, and capacitor C l may remain at zero. The output DC signal of the SSCD 1120 provided to the DC power bus 1136 may be the same as the DC charging signal, thus powering the auxiliary load(s) 301 during charging.

[0284] Figures 13N-13O illustrate example techniques for controlling the components of the example embodiment of system 100 shown in Figures 13A (or 13C) and 13D for charging energy source 206 in a two-motor embodiment. Figure 13N illustrates an example of an equivalent rectifier circuit 1386 during charging in a two-motor embodiment. Figure 13O illustrates an example of an equivalent module pack configuration 1387 during charging in a two-motor embodiment.

[0285] To charge the energy sources 206 of the arrays 700-A through 700-W of module packs 1110, the control system 102 can couple the charging source 150 to the arrays 700-A through 700-W of module packs 1110 and route a charging signal to the energy sources 206 of the arrays 700. To do so, the control system 102 or SSCD controller 1122 can open switches SA1, SB1, and SC1 to disconnect the module pack 1110 and charging source 150 from the motor 101-1. The control system 102 or SSCD controller 1122 can also open switches SU1, SV1, and SW1 to disconnect the module pack 1110 and charging source 150 from the motor 101-2.

[0286] Control system 102 can close switches SA2, SB2, SC2, SU2, SV2, and SW2 to allow a charging signal to reach arrays 700-A through 700-W from charging source 150. Control system 102 can also close switches SN1 through SN3 to couple common neutral points N1 through N3 to SSCD 1120. When using DC charging source 150 for DC charging, control system 102 can close switches SCH2, SCH3, and SCH5 through SCH8 to couple DC charging source 150 to arrays 700-A through 700-W and SSCD 1120 via cable 1134 and ports A through C and U through W. When AC charging is performed using AC charging source 150, control system 102 can close switches SCH1 and SCH4 to couple AC charging source 150 to arrays 700-A through 700-W and SSCD 1120 via cable 1134 and ports A and U.

[0287] SSCD controller 1122 can also close relay 1361. For DC charging, this switch configuration results in an equivalent rectifier circuit 1384 and equivalent module pack configuration 1385 in which DC charging signals are provided to arrays 700-A through 700-W and diode segments DSU through DSW and DSA through DSC via ports A through C and U through W of connectors 1310-1 and 1310-2. A positive DC charging signal can be provided to arrays 700-A through 700-C, and a negative DC charging signal can be provided to arrays 700-U through 700-W. During charging, SSCD controller 1122 can be bypassed because a DC voltage naturally forms from the DC charging signal.

[0288] The positive DC charging signal is routed to diode segments DSA through DSC via ports A through C of connectors 1310-1 and 1310-2, and the negative DC charging signal is routed to diode segments DSU through DSW via ports U through W of connectors 1310-1 and 1310-2. In this configuration, the DC charging signal is applied to capacitor C by sending the positive DC charging signal to DC+ line 1363-1, the negative DC charging signal to DC- line 1363-3, and neutrals N1 through N3 to intermediate DC line 1363-2. u and capacitor C l and to half the voltage level of charging source 150. The output DC signal of SSCD 1120 provided to DC power bus 1136 can be the same as the DC charging signal, thus powering auxiliary load(s) 301 during charging.

[0289] The above-described embodiments can be implemented to power various types of three-phase AC motors, such as wye-connected motors and delta-connected motors. By simply rotating connector 1310-2 and dynamically adding or removing bus bars, the same module pack 1110 and SSCD 1120 can be used for both single-motor control and two-motor control, simplifying manufacturing and increasing the flexibility of systems 100 that include these module packs 1110 and SSCDs 1120. This also allows the same hardware to be installed in front-wheel drive (FF), rear-wheel drive (FR), and all-wheel drive (AWD) EVs.

[0290] 14A-14K show additional embodiments of system 100 including a module pack 1110 and an SSCD 1120. In these embodiments, the same module pack 1110 and SSCD 1120 can be used for both single motor control and two motor control without rotating connectors or adding or removing bus bars. These embodiments can be used for open winding motors in single motor embodiments, but may not be compatible with all types of motors in single motor embodiments.

[0291] Figure 14A is a block diagram of an example embodiment of a modular energy system 100 having a module pack 1110 and an SSCD 1120 for powering two motors 101-1 and 101-2 and one or more auxiliary load(s) 301. The system 100 of Figure 14A is similar to the system 100 of Figure 13A, but has a different connector configuration for the cable 1134 and a different neutral connection.

[0292] In this embodiment, module pack 1110 includes connector 1310-3 configured to releasably mate with a connector on cable 1134. SSCD 1120 may also include connector 1310-4 (FIG. 14C) for releasably mating with a connector on cable 1134. The connectors on both ends of cable 1134 may have the same configuration as connector 1310-3. That is, the connectors on both ends of cable 1134 may have the same ports in the same orientation as shown in FIG. 14A.

[0293] Like connector 1310-1, connector 1310-3 includes ports A through C for coupling to system I / O ports SIO1 of arrays 700-A through 700-C via lines 1350-A through 1350-C and 1340-A through 1340-C, respectively, and ports U through W for coupling to system I / O ports SIO1 of arrays 700-U through 700-W via lines 1350-U through 1350-W and 1340-U through 1340-W, respectively. However, rather than the three neutral ports of connector 1310-1, connector 1310-3 includes one neutral port N that couples to the common neutral of segments AU, BV, and CW via switch SN1 and SIO port SIO7 of module pack 1110. Example techniques for controlling system 100 of FIG. 14A are described below with reference to FIGS. 14G-14I.

[0294] Figure 14B is a block diagram of an example embodiment of a modular energy system 100 having a module pack 1110 and an SSCD 1120 for powering a single motor 101 and one or more auxiliary load(s) 301. The system 100 of Figure 14B is similar to the system 100 of Figure 13B, but has a different connector configuration for the cable 1134 and a different neutral connection. In particular, this embodiment uses the same connector 1310-3 and associated connections as the embodiment of Figure 14A.

[0295] Additionally, the phase outputs of all six arrays 700-A through 700-W are coupled to motor 101-2. In particular, system I / O port SIO1 of arrays 700-U, 700-V, and 700-W is selectively coupled to motor 101-1 via lines 1450-U, 1450-V, and 1450-W and their switches SU1, SV1, and SW1, respectively. In this embodiment, arrays 700-A through 700-W are configured and / or operated such that system I / O port SIO1 of each array 700-A through 700-W is a phase port and system I / O port SIO2 is a neutral port.

[0296] In this configuration, motor 101-1 may be an open-winding motor 101-1 that is controlled based on voltage differences between the phase outputs of arrays 700-A through 700-C and the corresponding phase outputs of arrays 700-U through 700-W (e.g., based on the difference between the AC voltage output of array 700-A and the AC voltage output of array 700-U, the difference between the AC voltage output of array 700-B and the AC voltage output of array 700-V, and the difference between the AC voltage output of array 700-C and the AC voltage output of array 700-W). Example techniques for controlling system 100 of FIG. 14A are described below with reference to FIGS. 14D-14F.

[0297] FIG. 14C is a block diagram of an example embodiment of the SSCD 1120 for powering an auxiliary load. This embodiment of the SSCD 1120 is similar to the embodiment of the SSCD 1120 shown in FIG. 13D, but has a different connector 1310-4 for mating with a corresponding connector on the cable 1134 and does not include the relay 1361. The relay 1361 is not used here because an equivalent configuration of the SSCD 1120 can be used for one-motor control and two-motor control. This embodiment of the SSCD 1120 can be used as the SSCD for each of the embodiments shown in FIGS. 14A-14B and described herein.

[0298] Both connectors 1310-3 and 1310-4 have the same ports, A, B, C, U, V, W, and N, which may be configured the same. Ports with the same identifiers on both connectors 1310-3 and 1310-4 are coupled by conductors in cable 1134. For example, port A of connector 1310-3 is coupled to port A of connector 1310-4 via conductors.

[0299] FIG. 14D is a diagram showing an example of an equivalent rectifier circuit when a single motor is controlled, and FIG. 14E is a diagram showing an example of an equivalent module pack configuration when a single motor is controlled.

[0300] To operate motor 101-1, control system 1122 can close switches SA1, SA2, SB1, SB2, SC1, and SC2 to couple the phase outputs of arrays 700-A, 700-B, and 700-C to motor 101-1. Similarly, control system 102 can close switches SU1, SU2, SV1, SV2, SW1, and SW2 to couple the phase outputs of arrays 700-U, 700-V, and 700-W to motor 101-1, where the phase outputs of arrays 700-A through 700-C are coupled to system I / O ports SIO4 through SIO6 of SSCD 1120 and to diode segments DSA through DSC, respectively. Similarly, the phase outputs of arrays 700-U through 700-W are coupled to system I / O ports SIO1 through SIO3 of SSCD 1120 and to diode segments DSU through DSW, respectively.

[0301] The control system 102 can also open switches SCH1-SCH4 to isolate the charging source 150 from the components of the system 100. The controller 102 or the SSCD controller 1122 can also close switch SN1 to couple the common neutral points N1-N3 of the array 700 of module packs 1110 to the intermediate DC line 1363-2.

[0302] In the illustrated configuration, the phase outputs of arrays 700-A through 700-C and / or the phase outputs of arrays 700-U through 700-W are coupled to capacitors C during operation of motor 101-1 to provide output DC signals to auxiliary load(s) 301, as described in more detail herein. u and C l Charge the battery.

[0303] Figure 14F is a diagram of an example control scheme for single motor control using the system 100 of Figures 14A and 14C. The control scheme is similar to Figure 13H, but includes the use of module feedback signals by the SSCD controller 1122 to implement balancing techniques.

[0304] External motor controller 104 is configured to provide control information to SSCD controller 1122 via communication path or link 1135. This external control information may include a modulation index for each phase of the AC signal being supplied to motor 101-1, a modulated reference signal for each phase, or a modulation index and reference signal for each phase, or other control information.

[0305] Each segment of the array (e.g., segments AU, BV, and CW) can output a single-phase AC signal that includes a superposition of the output voltages from the modules of the array within the segment. For single-motor control, the external control information for a phase can be information for the segment (e.g., the segment with the corresponding phase angle) that outputs the AC signal for that phase. In the illustrated example, the external control information would include control information for array segment AU, array segment BV, and array segment CW.

[0306] Motor controller 104 may generate external control information based on a reference signal for motor control, a motor feedback signal received from motor 101-1 via communication path or link 1391, and / or a module feedback signal received from control system 102 of module pack 1110 via communication path or link 1133, as described above with reference to FIGURE 13H. Motor controller 104 may provide the external control information to SSCD controller 1122 via communication path or link 1135.

[0307] The SSCD controller 1122 is configured to process external control information and generate processed control information based on a reference signal of the SSCD 1120 (e.g., a reference value for the output DC signal), an SSCD feedback signal received from the SSCD 1120 via communication path or link 1132, and / or a module feedback signal received from the control system 102 of the module pack 1110 via communication path or link 1133. The processed control information may include a modulation index for each phase or a modulated reference signal for each phase.

[0308] The SSCD feedback signal may include, for example, the sensed voltage and / or current of the SSCD 1120. For example, the SSCD feedback signal may include the sensed voltage and / or current of the capacitor C u The voltage level V c,u , capacitor C l The voltage level V c,l , inductor L u The current I passing through L,u , and / or inductor L i The current I passing through L,l may include:

[0309] In this example, the module feedback signal is, for example, OC A ~OC WThe operational characteristics may include one or more operational characteristics of each array 700-A through 700-W, designated as: As described above, the operational characteristics may include, for example, a combined SOC, SOH, temperature, voltage, current, SOP, and / or SOE of the arrays 700-A through 700-W.

[0310] Processing the control information may include adjusting the control information, e.g., adjusting a modulation index for one or more phases and / or a modulation reference signal for one or more phases. Generally, the SSCD controller 1122 may adjust the control information to adjust the DC signal output by the SSCD 1120 to the auxiliary load(s) 301. For example, the SSCD controller 1122 may adjust the control information to adjust the voltage level and / or current level of the DC signal output to the DC power bus 1136.

[0311] To adjust the voltage level of the output DC signal, the SSCD controller 1122 adjusts the capacitance of the capacitor C so that the voltage level of the output DC signal is the sum of these voltage levels. u The voltage level V c,u and / or capacitor C l The voltage level V c,l In some embodiments, the SSCD controller 1122 can adjust the voltage level V c,u and V c.l The present invention can be configured to balance the above.

[0312] The SSCD controller 1122 adjusts the external control information to c,u and V c.l Adjust the capacitor C from the module pack 1110. u and C l For example, if the voltage level of the output DC signal is lower than the reference voltage of the output DC signal, the SSCD controller 1122 may adjust the external control information to transfer energy from the module pack 1110 to the capacitor C u and C lIf the voltage level of the output DC signal is greater than the reference voltage of the output DC signal, the SSCD controller 1122 adjusts the external control information to transfer the current from the module pack 1110 to the capacitor C u and C l This can reduce the amount of energy being transferred to the

[0313] The SSCD controller 1122 adjusts the external control information to transfer the capacitor C u and C l By increasing or decreasing the amount of energy transferred to the voltage level V c,u and V c.l For example, the SSCD controller 1122 can compare a reference voltage for each capacitor (which may be, for example, half the reference voltage for the output DC signal) to the sensed value for the capacitor. One or both of these comparisons, and / or the reference voltage for the output DC signal and V c,u and V c.l Using these comparisons, SSCD controller 1122 removes capacitor C from module pack 1110. u and C l It can be determined whether to increase or decrease the amount of energy being transferred to the

[0314] The SSCD controller 1122 adjusts the external control information to drive the capacitor C u and C l If it is determined to increase or decrease the amount of energy being transferred to the SSCD controller 122, the SSCD controller 122 may adjust the modulation index and / or modulated reference signal in the same manner for all three phases, for example, by increasing or decreasing the value by the same amount, or in different manners for balancing purposes.

[0315] Processing the external control information can also include adjusting the external control information to balance one or more operating characteristics of arrays 700-A through 700-W. For an open-winding motor, increasing or decreasing the voltage of both in-phase phase signals (e.g., the phase output of array 700-A and the phase output of array 700-U) by the same amount does not affect the control of motor 101-2 because the increases and decreases cancel each other out.

[0316] The SSCD controller 1122 can perform subpack balancing techniques to balance one or more operating characteristics of the arrays 700-A through 700-W. One type of subpack balancing involves balancing operating characteristics on a segment-by-segment basis, which can be referred to as segment subpack balancing. In this example, the SSCD controller 1122 can adjust the amount of energy output by one or more segments AU, BV, and CW to balance one or more combined operating characteristics of the segments AU, BV, and CW and / or to balance one or more combined operating characteristics of the arrays 700-A through 700-W within the segments AU, BV, and CW. In this manner, increasing the amount of energy output by a segment AU, BV, or CW does not affect motor control but can achieve balance between the segments AU, BV, and CW and the arrays 700-A through 700-W and provide regulated DC power to the auxiliary load(s) 301. This is a form of phase-to-phase balancing using segment subpacks.

[0317] In segment subpack balancing, the SSCD control device 1122 can select the segment AU, BV, or CW that contributes more to powering the auxiliary load(s) 301 based on the combined operating characteristic(s) of each segment AU, BV, and CW and / or the combined operating characteristic(s) of each array 700-A to 700-W.

[0318] For example, if the combined SOC of sub-packs AU is greater than the combined SOC of sub-packs BV and CW, then SSCD controller 1122 may select segment AU to output more energy to power auxiliary load(s) 301. In this example, SSCD controller 1122 may adjust the control information for sub-packs AU (e.g., by increasing the modulation index for arrays 700-A and 700-U) so that arrays 700-A and 700-U output more energy. Similarly, SSCD controller 1122 may adjust the control information for sub-packs BV and / or CW (e.g., by decreasing the modulation index for arrays 700-B and 700-V and / or arrays 700-C and 700-W) so that arrays 700-B and 700-V and / or arrays 700-C and 700-W output less energy.

[0319] In another example, if the SOC of array 700-A is lower than the SOC of each of the other arrays 700-B through 700-W, SSCD controller 1122 may reduce the amount of energy output by arrays 700-A and 700-U and use capacitor C to power auxiliary load(s) 301. u and C l The SSCD controller 1122 may select segment BV and / or segment CW that outputs more energy to be transferred to the SSCD. To do this, the SSCD controller 1122 may adjust the external control information to decrease the modulation index for arrays 700-A and 700-U in segment AU and increase the modulation index for arrays 700-B and 700-V in segment BV and / or the modulation index for arrays 700-C and 700-W in segment CW. In this way, the SOCs of arrays 700-B, 700-C, 700-V, and 700-W decrease faster than the SOC of arrays 700-A and 700-U, balancing the SOCs among arrays 700-A through 700-W.

[0320] In this embodiment, the SSCD controller 1122 can be configured to perform multi-phase subpack balancing between subpacks A, B, C, and UV, W. Because both of these multi-phase subpacks supply AC power to motor 101-1 in this embodiment, the SSCD controller 1122 can adjust the amount of energy supplied to motor 101-1 by subpacks A, B, C, and UV, W to balance one or more aggregate operating characteristics between subpacks A, B, C, and UV, W. For example, the SSCD controller 1122 can select subpack A, B, C, or UV, W that contributes more to motor 101-1 based on the aggregate operating characteristic(s) of each subpack A, B, C, and UV, W and / or the aggregate operating characteristic(s) of each array 700-A through 700-W.

[0321] For example, if the combined SOC of subpacks A, B, C is greater than the combined SOC of subpacks U, V, and W, SSCD controller 1122 may select subpack A, B, C to output more energy to power motor 101-1. In this example, SSCD controller 1122 may adjust the control information for arrays 700-A through 700-C in subpack A, B (e.g., by increasing the modulation index for arrays 700-A through 700-C) to output more energy. Similarly, SSCD controller 1122 may adjust the control information for subpacks U, V, and W (e.g., by decreasing the modulation index for arrays 700-U through 700-W) to output less energy.

[0322] In another example, if the SOC of array 700-A is lower than the SOC of each of the other arrays 700-B through 700-W, SSCD controller 1122 may reduce the amount of energy output by arrays 700-A through 700-C in subpacks A, B, C. To do this, SSCD controller 1122 may adjust external control information to decrease the modulation index for arrays 700-A through 700-C in subpacks A, B, C, and increase the modulation index for arrays 700-U through 700-W in subpacks U, V, and W.

[0323] The SSCD controller 1122 provides the processed control information to the control system 102 of the module pack 1110. As described above, the control system 102 may include one or more MCDs 112, LCDs 114, and an array controller 900 for each array 700, or a controller 950 for multiple arrays 700, e.g., a controller 950 for all arrays 700 in the module pack 1110, or a controller 950 for each segment. In this embodiment, the control system 102 may include an array controller 900 for each array 700-A through 700-W.

[0324] An array controller 900 for an array 700 can perform intra-phase balancing techniques to balance one or more operating characteristics of the modules 108 in the array 700. The controller 900 for an array 700 can receive processed control information for that array 700 (e.g., a processed modulation index for that array 700) and generate a modulation index for each module 108 of the array 700, as described herein, based on the processed control information and one or more operating characteristics of each module in the array 700. For example, the controller 900 for array 700-A can receive the processed modulation index for array 700-A and adjust the processed modulation index for each module 108 in array 700-A to balance one or more operating characteristics of the modules 108 in the array 700-A.

[0325] As described herein, MCD 112 can provide modulation indices and reference signals, or modulated reference signals, for modules 108 of array 700 to LCD 114, which controls modules 108 to generate the AC signals output by array 700. Here, the AC signals generated by arrays 700-A through 700-W are provided to motor 101-1.

[0326] Additionally, the AC signals generated by arrays 700-A through 700-C and / or the AC signals generated by arrays 700-U through 700-W are supplied to SSCD 1120 via cable 1134. SSCD 1120 converts the AC signals to DC signals and outputs the DC signals to DC power bus 1136 to power auxiliary load 301.

[0327] 14G-14I illustrate example techniques for controlling components of the example embodiment of system 100 shown in FIGS. 14A and 14C for supplying and regulating AC power to two motors 101-1 and 101-2 of an EV and for supplying and regulating DC power to auxiliary load(s) 301.

[0328] FIG. 14G illustrates an example of an equivalent rectifier circuit 1480 for two-motor control, and FIG. 14H illustrates an example of an equivalent module pack configuration 1483 for two-motor control. In this example, equivalent rectifier circuit 1480 is the same as equivalent rectifier circuit 1480 of FIG. 14D because connectors 1310-3 and 1310-4 are the same in both embodiments and the switch configurations of both systems 100 are the same. Equivalent module pack configuration 1483 differs from equivalent module pack configuration 1481 because arrays 700-U through 700-W are coupled to motor 101-2 instead of motor 101-1.

[0329] Figure 14I shows an example of a two-motor control scheme. The control scheme is similar to that of Figure 13K, but includes a balancing technique.

[0330] 13K, external motor controller 104-1 is configured to generate and provide external control information for arrays 700-A through 700-C to SSCD controller 1122 via communication path or link 1135-1. Similarly, external motor controller 104-2 is configured to generate and provide external control information for arrays 700-U through 700-W to SSCD controller 1122 via communication path or link 1135-2.

[0331] SSCD controller 1122 is configured to process external control information from each motor controller 104-1 and 104-2 and generate processed control information for subpacks ABC and UVW based on a voltage reference value of SSCD 1120 (e.g., a reference value for the output DC signal), an SSCD feedback signal received from SSCD 1120 via communication path or link 1132, and / or a module feedback signal received from control system 102 of module pack 1110 via communication path or link 1133. The processed control information for subpack ABC or UVW may include a modulation index for each phase of that subpack ABC or UVW or a modulated reference signal for each phase of that subpack ABC or UVW. Thus, the processed control information for subpack ABC or UVW may include a modulation index or a modulated reference signal for each array 700 of subpacks ABC or UVW.

[0332] The SSCD feedback signal may include, for example, the sensed voltage and / or current of the SSCD 1120. For example, the SSCD feedback signal may include the sensed voltage and / or current of the capacitor C u The voltage level V c,u , capacitor C l The voltage level V c,l , inductor L u The current I passing through L,u , and / or inductor L i The current I passing through L,l may include:

[0333] In this example, the module feedback signal is, for example, OC A ~OC W The operational characteristics may include one or more operational characteristics of each array 700-A through 700-W, designated as: As described above, the operational characteristics may include, for example, a combined SOC, SOH, temperature, voltage, current, SOP, and / or SOE of the arrays 700-A through 700-W.

[0334] Processing the control information may include adjusting the control information, e.g., adjusting a modulation index for one or more phases and / or a modulation reference signal for one or more phases. The SSCD controller 1122 may adjust the control information to adjust the DC signal output by the SSCD 1120 to the auxiliary load(s) 301. For example, the SSCD controller 1122 may adjust the control information to adjust the voltage level and / or current level of the DC signal output to the DC power bus 1136.

[0335] To adjust the voltage level of the output DC signal, the SSCD controller 1122 adjusts the capacitance of the capacitor C so that the voltage level of the output DC signal is the sum of these voltage levels. u The voltage level V c,u and capacitor C l The voltage level V c,l In some embodiments, the SSCD controller 1122 can adjust the voltage level V c,u and V c.l The present invention can be configured to balance the above.

[0336] The SSCD controller 1122 adjusts the external control information for one or both of the subpacks ABC and UVW to V c,u and V c.l Adjust the capacitor C from the module pack 1110. u and C l For example, if the voltage level of the output DC signal is lower than the reference voltage of the output DC signal, the SSCD controller 1122 adjusts the external control information for subpacks A, B, C, and U, V, and W to transfer energy from module pack 1110 to capacitor C. u and C l If the voltage level of the output DC signal is higher than the reference voltage of the output DC signal, the SSCD controller 1122 adjusts the external control information for subpacks A, B, C, and U, V, and W to transfer the energy from the module pack 1110 to the capacitor C. u and Cl This can reduce the amount of energy being transferred to the

[0337] The SSCD controller 1122 adjusts the external control information for one or both of the subpacks ABC and UVW to set the voltage level V c,u and V c.l Balance the capacitor C from the module pack 1110. u and C l For example, the SSCD controller 1122 can compare a reference voltage for each capacitor (which may be, for example, half the reference voltage for the output DC signal) to the sensed value for the capacitor. One or both of these comparisons, and / or the reference voltage for the output DC signal and V c,u and V c.l Using these comparisons, SSCD controller 1122 removes capacitor C from module pack 1110. u and C l The amount of energy being transferred to the target can be increased, decreased, or not adjusted.

[0338] The SSCD controller 1122 adjusts the external control information for one or both of the subpacks ABC and UVW to control the capacitor C u and C l If it is determined to increase or decrease the amount of energy being transferred to the subpack(s), the SSCD controller 122 may adjust the modulation index and / or modulated reference signal in the same manner for all three phases of the subpack(s), for example, by increasing or decreasing the value by the same amount, or in different manners for balancing purposes.

[0339] 14F, SSCD controller 1122 can also perform multi-phase balancing techniques to balance one or more combined operating characteristics of subpacks A, B, C, and one or more combined operating characteristics of subpacks U, V, and W. To achieve this balancing without affecting the operation of motors 101-1 and 101-2, SSCD controller 1122 can be configured to make the same adjustments to the control information for each phase of subpacks A, B, C, or U, V, and W, adjusting the common-mode voltage of the AC signals supplied to motor 101-1 or motor 101-2.

[0340] The SSCD controller 1122 provides the processed control information to the control system 102 of the module pack 1110. As described above, the control system 102 may include one or more MCDs 112, LCDs 114, and an array controller 900 for each array 700, or a controller 950 for multiple arrays 700, e.g., a controller 950 for all arrays 700 in the module pack 1110, or a controller 950 for each segment. In this embodiment, the control system 102 may include an array controller 900 for each array 700-A through 700-W.

[0341] An array controller 900 for an array 700 can perform intra-phase balancing techniques to balance one or more operating characteristics of the modules 108 in the array 700. The controller 900 for an array 700 can receive processed control information for that array 700 (e.g., a processed modulation index for that array 700) and generate a modulation index for each module 108 of the array 700, as described herein, based on the processed control information and one or more operating characteristics of each module in the array 700. For example, the controller 900 for array 700-A can receive the processed modulation index for array 700-A and adjust the processed modulation index for each module 108 in array 700-A to balance one or more operating characteristics of the modules 108 in the array 700-A.

[0342] As described herein, MCD 112 can provide modulation indices and reference signals, or modulated reference signals, for modules 108 of array 700 to LCD 114, which controls modules 108 to generate the AC signals output by array 700, where the AC signals generated by arrays 700-A through 700-C are supplied to motor 101-1 and the AC signals generated by arrays 700-U through 700-W are supplied to motor 101-2.

[0343] Furthermore, the AC signals generated by arrays 700-A through 700-C and the AC signals generated by arrays 700-U through 700-W are supplied to SSCD 1120 via cable 1134. SSCD 1120 converts the AC signals to DC signals and outputs the DC signals to DC power bus 1136 to power auxiliary load 301.

[0344] The control system 102 can be configured to control the charging of the energy sources 206 of the modules 108 of the module pack 1110 while supplying DC power to the auxiliary load(s) 301 in both single motor and two motor embodiments.

[0345] Figures 14J-14K illustrate example techniques for controlling components of the example embodiment of system 100 shown in Figures 14A-14C for charging energy source 206 in both single-motor and dual-motor embodiments. Figure 14J illustrates an example of an equivalent rectifier circuit 1480 during charging in single-motor and dual-motor embodiments. Figure 14K illustrates an example of an equivalent module pack configuration 1484 during charging in single-motor and dual-motor embodiments.

[0346] In this example, the equivalent circuit is the same for single motor charging and dual motor charging. Additionally, the equivalent rectifier circuit 1480 is the same as the equivalent rectifier circuit 1480 in Figures 14D and 14G.

[0347] To charge the energy sources 206 of the arrays 700 of module packs 1110, the control system 102 can couple the charging source 150 to the arrays 700-A through 700-W of module packs 1110 and route the charging signal to the energy sources 206 of the arrays 700-A through 700-W. To do so, the control system 102 opens switches SA1, SB1, and SC1 to disconnect the module pack 1110 and charging source 150 from the motor 101-1. The control system 102 can also open switches SU1, SV1, and SW1 to disconnect the module pack 1110 and charging source 150 from either the motor 101-1 or the motor 101-2 (depending on whether the single-motor or two-motor embodiment is used).

[0348] Control system 102 may close switches SA2, SB2, SC2, SU2, SV2, and SW2 to allow a charging signal to reach arrays 700-A through 700-W from charging source 150. Control system 102 may also close switch SN1 to couple common neutral points N1 through N3 to SSCD 1120. When DC charging is performed using DC charging source 150, control system 102 may close switches SCH2, SCH3, and SCH5 through SCH8 to couple DC charging source 150 to arrays 700-A through 700-W and SSCD 1120 via cable 1134 and ports A through C and U through W of connector 1310-3.

[0349] For DC charging, this switch configuration results in an equivalent rectifier circuit 1480 and equivalent module pack configuration 1484 where DC charging signals are provided to arrays 700-A through 700-W and diode segments DSU through DSW and DSA through DSC. Positive DC charging signals can be provided to arrays 700-A through 700-C, and negative DC charging signals can be provided to arrays 700-U through 700-W.

[0350] During charging, the SSCD controller 1122 can be bypassed because the DC voltage naturally consists of the DC charging signal coupled to the SSCD 1120. A positive DC charging signal is sent through ports A through C of the connector 1310-1 to diode segments DA through DC, and a negative DC charging signal is sent through ports U through W of the connector to diode segments DU through DW. The DC charging signal is sent to each capacitor C u and C l to half the DC charging signal. The output DC signal of the SSCD 1120 provided to the DC power bus 1136 can be the same as the DC charging signal.

[0351] 15A-15K illustrate additional embodiments of system 100 including a module pack 1110 and an SSCD 1120. Similar to the embodiments of FIGS. 14A-14K, these embodiments allow the same module pack 1110 and SSCD 1120 to be used for both single and two-motor control without rotating connectors or adding or removing bus bars. These embodiments can be used with open-winding motors in single-motor embodiments, but may not be compatible with all types of motors in single-motor embodiments.

[0352] Figure 15A is a block diagram of an example embodiment of a modular energy system 100 having a module pack 1110 and an SSCD 1120 for powering two motors 101-1 and 101-2 and one or more auxiliary load(s) 301. The system 100 of Figure 15A is similar to the system 100 of Figure 14A, except for the connector configuration for the cable 1134, as the neutral point is not connected to the SSCD 1120.

[0353] In this embodiment, module pack 1110 includes connector 1310-5 configured to releasably mate with a connector on cable 1134. SSCD 1120 may also include connector 1310-6 (FIG. 15C) for releasably mating with a connector on cable 1134. The connectors on both ends of cable 1134 may have the same configuration as connector 1310-5. That is, the connectors on both ends of cable 1134 may have the same ports in the same orientation as shown in FIG. 15A.

[0354] Like connector 1310-3, connector 1310-5 includes ports A through C for coupling to phase array ports SI01 of arrays 700-A through 700-C via lines 1350-A through 1350-C and 1340-A through 1340-C, respectively, and ports U through W for coupling to phase array ports SI01 of arrays 700-U through 700-W via lines 1350-U through 1350-W and 1340-U through 1340-W, respectively. However, connector 1310-5 does not include a neutral port, and there is no system I / O port SI07 or switch SN1 for coupling the common neutral of segments AU, BV, and CW to cable 1134 and SSCD 1220. Example techniques for controlling system 100 of FIG. 15A are described below with reference to FIGS. 15H through 15K.

[0355] Figure 15B is a block diagram of an example embodiment of a modular energy system 100 having a module pack 1110 and an SSCD 1120 for powering a single motor 101 and one or more auxiliary load(s) 301. The system 100 of Figure 15B is similar to the system 100 of Figure 14B, but differs in the connector configuration for the cable 1134. In particular, this embodiment uses the same connector 1310-5 as the embodiment of Figure 15A, and does not include system I / O port SIO7 or switch SN1 for coupling the common neutral of segments AU, BV, and CW onto the cable 1134 and SSCD 1220.

[0356] Figure 15C is a block diagram of an example embodiment of an SSCD 1120 for powering an auxiliary load. This embodiment of the SSCD 1120 can be used as the SSCD for each of the embodiments shown in Figures 15A-15B and described herein. The SSCD 1120 of this embodiment differs from that of Figures 13D and 14C because this embodiment does not include an intermediate DC line and therefore does not couple to the common neutral of the array 700 of module packs 1110.

[0357] The SSCD 1120 includes system I / O ports SIO1 to SIO6 for coupling to connector 1310-6 of cable 1134, and system I / O ports SIO7 and SIO8 for coupling to DC+ line 1136-1 and DC- line 1136-2, respectively, of a DC bus 1366 that routes DC power output by the SSCD 1120 to auxiliary load(s) 301.

[0358] In particular, system I / O ports SIO1, SIO2, and SIO3 of SSCD 1220 are coupled to phase port SIO1 of arrays 700-U, 700-V, and 700-W, respectively, via cables 1134. Similarly, system I / O ports SIO4, SIO5, and SIO6 of SSCD 1220 are coupled to phase port SIO1 of arrays 700-A, 700-B, and 700-C, respectively, via cables 1134.

[0359] The SSCD 1220 may include a rectifier circuit including a diode circuit 1360 and a filter circuit 1362. The diode circuit 1360 is configured as two three-phase full-wave rectifiers, one for arrays 700-A through 700-C and the other for arrays 700-U through 700-W. The diode circuit 1360 includes diodes D1 through D12. The diode circuit 1360 includes three diode segments DSU, DSV, and DSW that form the three-phase full-wave rectifiers for arrays 700-U through 700-W. The rectifier circuit 1360 also includes three diode segments DSA, DSB, and DSC to form the three-phase full-wave rectifiers for arrays 700-A through 700-C. Each diode segment includes two diodes to which the phase outputs of the arrays 700 are coupled. For example, diode segment DSU includes diodes D1 and D2, and phase port SI01 of array 700-U is coupled between diodes D1 and D2 via cable 1134. The two diodes in each segment are coupled between DC+ line 1363-1 and DC- line 1363-3.

[0360] Diode circuit 1360 is coupled to filter circuit 1362 via DC lines 1363-1 and 1363-3. Filter circuit 1362 includes an inductor L on DC+ line 1363-1, a resistor R coupled between DC+ line 1363-1 and intermediate DC line 1363-2, and a resistor R u , and a capacitor C coupled between the DC+ line 1363-1 and the DC- line 1363-3.

[0361] Diode circuit 1360 is configured to convert the three-phase AC signal into voltage pulses of the same polarity, e.g., positive polarity, between DC+ line 1363-1 and DC- line 1363-3. Capacitor C and inductor L are configured to filter these pulses to produce a constant or near-constant DC output signal between DC+ line 1136-1 and DC- line 1136-3 of DC bus 136. Because capacitor C does not function as an energy buffer, whereas the capacitors in Figures 13D and 14C may function as an energy buffer, in this embodiment, capacitor C may be smaller and / or have a lower rating than the capacitors in Figures 13D and 14C.

[0362] As will be explained in more detail below, the SSCD controller 1122 controls the voltage level V across the capacitor C. c, can be adjusted to provide a target output DC voltage level between the DC+ line 1136-1 and the DC- line 1136-3. The SSCD 1120 adjusts the voltage level V across the capacitor C. c , output current I out , and the current I through the inductor L L The SSCD controller 1122 may include sensors for sensing the voltage and current of the sensor. The sensors may include voltage sensors and current sensors. The outputs of the sensors may be communicatively coupled to the SSCD controller 1122, for example, using a communication path or link 1132. For example, the communication path or link 1132 may be communicatively coupled to each sensor and relay 1361 using one or more conductors for each component.

[0363] SSCD 1120 includes a discharge circuit 1364 coupled to DC lines 1363-1 through 1363-3. Discharge circuit 1364 discharges capacitor C in response to detecting a condition such as a fault or short circuit and / or during an orderly system shutdown. u and C lThe module pack 1110 may include a disconnect feature, such as a contactor, that can open to disconnect the module pack 1110 and its components upon detection of a condition. This prevents energy from being transferred to the capacitor C. However, if the capacitor C The stored energy must also be safely discharged. The discharge circuit 1364 can safely discharge the capacitor C without sending energy to the load(s) 301 via the DC bus 1136 or the module pack 1110.

[0364] 15D-15F illustrate example techniques for controlling components of the example embodiment of system 100 shown in FIGS. 15B and 15C for supplying and regulating AC power to a single motor 101-1 of an EV and supplying and regulating DC power to auxiliary load(s) 301.

[0365] FIG. 15D is a diagram showing an example of an equivalent rectifier circuit 1580 when a single motor is controlled, and FIG. 15E is a diagram showing an example of the configuration of an equivalent module pack 1581 when a single motor is controlled.

[0366] When operating motor 101-1, control system 102 can close switches SA1, SA2, SB1, SB2, SC1, and SC2 to couple the phase outputs of arrays 700-A, 700-B, and 700-C to motor 101-1. Control system 102 can also open switches SCH1-SCH4 to isolate charging source 150 from the components of system 100. Control system 102 can also close switches SU1, SU2, SV1, SV2, SV1, and SV2 to couple the phase outputs of arrays 700-U, 700-V, and 700-W to motor 101-1.

[0367] In the illustrated configuration, the phase outputs of arrays 700-A through 700-C and / or the phase outputs of arrays 700-U through 700-W charge capacitor C during operation of motor 101-1 to provide an output DC signal to auxiliary load(s) 301, as described in more detail below.

[0368] Figure 15F is a diagram of an example control scheme for single motor control using the system 100 of Figures 15A and 15C. The control scheme is similar to that of Figure 14F, but differs depending on the configuration of the SSCD 1120.

[0369] External motor controller 104 is configured to provide control information to SSCD controller 1122 via communication path or link 1135. This external control information may include a modulation index for each phase of the AC signal being supplied to motor 101-1, a modulated reference signal for each phase, or a modulation index and reference signal for each phase, or other control information.

[0370] Each segment of the array (e.g., segments AU, BV, and CW) can output a single-phase AC signal that includes a superposition of the output voltages from the modules of the array within the segment. For single-motor control, the external control information for a phase can be information for the segment (e.g., the segment with the corresponding phase angle) that outputs the AC signal for that phase. In the illustrated example, the external control information would include control information for array segment AU, array segment BV, and array segment CW.

[0371] Motor controller 104 may generate external control information based on a reference signal for motor control, a motor feedback signal received from motor 101-1 via communication path or link 1391, and / or a module feedback signal received from control system 102 of module pack 1110 via communication path or link 1133, as described above with reference to FIGURE 13H. Motor controller 104 may provide the external control information to SSCD controller 1122 via communication path or link 1135.

[0372] The SSCD controller 1122 is configured to process external control information and generate processed control information based on a reference signal of the SSCD 1120 (e.g., a reference value for the output DC signal), an SSCD feedback signal received from the SSCD 1120 via communication path or link 1132, and / or a module feedback signal received from the control system 102 of the module pack 1110 via communication path or link 1133. The processed control information may include a modulation index for each phase or a modulated reference signal for each phase.

[0373] The SSCD feedback signal may include, for example, the sensed voltage and / or current of the SSCD 1120. For example, the SSCD feedback signal may include the voltage level Vc across the capacitor C and / or the current I through the inductor L. L may include:

[0374] In this example, the module feedback signal is, for example, OC A ~OC W The operational characteristics may include one or more operational characteristics of each array 700-A through 700-W, designated as: As described above, the operational characteristics may include, for example, a combined SOC, SOH, temperature, voltage, current, SOP, and / or SOE of the arrays 700-A through 700-W.

[0375] Processing the control information may include adjusting the control information, e.g., adjusting a modulation index for one or more phases and / or a modulation reference signal for one or more phases. Generally, the SSCD controller 1122 may adjust the control information to adjust the DC signal output by the SSCD 1120 to the auxiliary load(s) 301. For example, the SSCD controller 1122 may adjust the control information to adjust the voltage level and / or current level of the DC signal output to the DC power bus 1136. To adjust the voltage level of the output DC signal, the SSCD controller 1122 adjusts a voltage level V across the capacitor C such that the voltage level of the output DC signal is the same as this voltage level. c, can be adjusted.

[0376] The SSCD controller 1122 adjusts the external control information to c to increase or decrease the amount of energy being transferred from the module pack 1110 to capacitor C. For example, if the voltage level of the output DC signal is lower than the reference voltage of the output DC signal, the SSCD controller 1122 can adjust the external control information to increase the amount of energy being transferred from the module pack 1110 to capacitor C. If the voltage level of the output DC signal is greater than the reference voltage of the output DC signal, the SSCD controller 1122 can adjust the external control information to decrease the amount of energy being transferred from the module pack 1110 to capacitor C.

[0377] If the SSCD controller 1122 decides to adjust the external control information to increase or decrease the amount of energy being transferred to capacitor C, the SSCD controller 122 may adjust the modulation index and / or modulated reference signal in the same manner for all three phases, for example, by increasing or decreasing the value by the same amount, or in different manners for balancing purposes.

[0378] Processing the external control information can also include adjusting the external control information to balance one or more operating characteristics of arrays 700-A through 700-W. For an open-winding motor, increasing or decreasing the voltage of both in-phase phase signals (e.g., the phase output of array 700-A and the phase output of array 700-U) by the same amount does not affect the control of motor 101-2 because the increases and decreases cancel each other out.

[0379] The SSCD controller 1122 can perform subpack balancing techniques to balance one or more operating characteristics of the arrays 700-A through 700-W. One type of subpack balancing involves balancing operating characteristics on a segment-by-segment basis, which can be referred to as segment subpack balancing. In this example, the SSCD controller 1122 can adjust the amount of energy output by one or more segments AU, BV, and CW to balance one or more combined operating characteristics of the segments AU, BV, and CW and / or to balance one or more combined operating characteristics of the arrays 700-A through 700-W within the segments AU, BV, and CW. In this manner, increasing the amount of energy output by a segment AU, BV, or CW does not affect motor control but can achieve a balance between the segments AU, BV, and CW and the arrays 700-A through 700-W and provide regulated DC power to the auxiliary load(s) 301.

[0380] In segment subpack balancing, the SSCD control device 1122 can select the segment AU, BV, or CW that contributes more to powering the auxiliary load(s) 301 based on the combined operating characteristic(s) of each segment AU, BV, and CW and / or the combined operating characteristic(s) of each array 700-A to 700-W.

[0381] For example, if the combined SOC of sub-packs AU is greater than the combined SOC of sub-packs BV and CW, then SSCD controller 1122 may select segment AU to output more energy to power auxiliary load(s) 301. In this example, SSCD controller 1122 may adjust the control information for sub-packs AU (e.g., by increasing the modulation index for arrays 700-A and 700-U) so that arrays 700-A and 700-U output more energy. Similarly, SSCD controller 1122 may adjust the control information for sub-packs BV and / or CW (e.g., by decreasing the modulation index for arrays 700-B and 700-V and / or arrays 700-C and 700-W) so that arrays 700-B and 700-V and / or arrays 700-C and 700-W output less energy.

[0382] In another example, if the SOC of array 700-A is lower than the SOC of each of the other arrays 700-B through 700-W, SSCD controller 1122 may reduce the amount of energy output by arrays 700-A and 700-U and use capacitor C to power auxiliary load(s) 301. u and C l The SSCD controller 1122 may select segment BV and / or segment CW that outputs more energy to be transferred to the SSCD. To do this, the SSCD controller 1122 may adjust the external control information to decrease the modulation index for arrays 700-A and 700-U in segment AU and increase the modulation index for arrays 700-B and 700-V in segment BV and / or the modulation index for arrays 700-C and 700-W in segment CW. In this way, the SOCs of arrays 700-B, 700-C, 700-V, and 700-W decrease faster than the SOC of arrays 700-A and 700-U, balancing the SOCs among arrays 700-A through 700-W.

[0383] In this embodiment, the SSCD controller 1122 can be configured to perform multi-phase subpack balancing between subpacks A, B, C, and UV, W. Because both of these multi-phase subpacks supply AC power to motor 101-1 in this embodiment, the SSCD controller 1122 can adjust the amount of energy supplied to motor 101-1 by subpacks A, B, C, and UV, W to balance one or more aggregate operating characteristics between subpacks A, B, C, and UV, W. For example, the SSCD controller 1122 can select subpack A, B, C, or UV, W that contributes more to motor 101-1 based on the aggregate operating characteristic(s) of each subpack A, B, C, and UV, W and / or the aggregate operating characteristic(s) of each array 700-A through 700-W.

[0384] For example, if the combined SOC of subpacks A, B, C is greater than the combined SOC of subpacks U, V, and W, SSCD controller 1122 may select subpack A, B, C to output more energy to power motor 101-1. In this example, SSCD controller 1122 may adjust the control information for arrays 700-A through 700-C in subpack A, B (e.g., by increasing the modulation index for arrays 700-A through 700-C) to output more energy. Similarly, SSCD controller 1122 may adjust the control information for subpacks U, V, and W (e.g., by decreasing the modulation index for arrays 700-U through 700-W) to output less energy.

[0385] In another example, if the SOC of array 700-A is lower than the SOC of each of the other arrays 700-B through 700-W, SSCD controller 1122 may reduce the amount of energy output by arrays 700-A through 700-C in subpacks A, B, C. To do this, SSCD controller 1122 may adjust external control information to decrease the modulation index for arrays 700-A through 700-C in subpacks A, B, C, and increase the modulation index for arrays 700-U through 700-W in subpacks U, V, and W.

[0386] The SSCD controller 1122 provides the processed control information to the control system 102 of the module pack 1110. As described above, the control system 102 may include one or more MCDs 112, LCDs 114, and an array controller 900 for each array 700, or a controller 950 for multiple arrays 700, e.g., a controller 950 for all arrays 700 in the module pack 1110, or a controller 950 for each segment. In this embodiment, the control system 102 may include an array controller 900 for each array 700-A through 700-W.

[0387] An array controller 900 for an array 700 can perform intra-phase balancing techniques to balance one or more operating characteristics of the modules 108 in the array 700. The controller 900 for an array 700 can receive processed control information for that array 700 (e.g., a processed modulation index for that array 700) and generate a modulation index for each module 108 of the array 700, as described herein, based on the processed control information and one or more operating characteristics of each module in the array 700. For example, the controller 900 for array 700-A can receive the processed modulation index for array 700-A and adjust the processed modulation index for each module 108 in array 700-A to balance one or more operating characteristics of the modules 108 in the array 700-A.

[0388] As described herein, MCD 112 may provide modulation indices and reference signals, or modulated reference signals, for modules 108 of array 700 to LCD 114, which controls modules 108 to generate the AC signals output by array 700. Here, the AC signals generated by arrays 700-A through 700-C and arrays 700-U through 700-W are provided to motor 101-1.

[0389] Additionally, the AC signals generated by arrays 700-A through 700-C and / or the AC signals generated by arrays 700-U through 700-W are supplied to SSCD 1120 via cable 1134. SSCD 1120 converts the AC signals to DC signals and outputs the DC signals to DC power bus 1136 to power auxiliary load 301.

[0390] 15G-15I illustrate example techniques for controlling components of the example embodiment of system 100 shown in FIGS. 15A and 15C for supplying and regulating AC power to two motors 101-1 and 101-2 of an EV and for supplying and regulating DC power to auxiliary load(s) 301.

[0391] Figure 15G is a diagram showing an example of an equivalent rectifier circuit 1580 when two motors are controlled, and Figure 15H is a diagram showing an example of an equivalent module pack configuration 1583 when two motors are controlled. In this example, equivalent rectifier circuit 1580 is the same as equivalent rectifier circuit 1580 in Figure 15D. Equivalent module pack configuration 1583 differs from equivalent module pack configuration 1581 because arrays 700-U to 700-W are coupled to motor 101-2 instead of motor 101-1.

[0392] 15I is a diagram showing an example of a control method for two-motor control. The control method is similar to that shown in FIG. 14I, but differs depending on the configuration of the SSCD 1120.

[0393] 14I, external motor controller 104-1 is configured to generate and provide external control information for arrays 700-A through 700-C to SSCD controller 1122 via communication path or link 1135-1. Similarly, external motor controller 104-2 is configured to generate and provide external control information for arrays 700-U through 700-W to SSCD controller 1122 via communication path or link 1135-2.

[0394] SSCD controller 1122 is configured to process external control information from each motor controller 104-1 and 104-2 and generate processed control information for subpacks ABC and UVW based on a voltage reference value of SSCD 1120 (e.g., a reference value for the output DC signal), an SSCD feedback signal received from SSCD 1120 via communication path or link 1132, and / or a module feedback signal received from control system 102 of module pack 1110 via communication path or link 1133. The processed control information for subpack ABC or UVW may include a modulation index for each phase of that subpack ABC or UVW or a modulated reference signal for each phase of that subpack ABC or UVW. Thus, the processed control information for subpack ABC or UVW may include a modulation index or a modulated reference signal for each array 700 of subpacks ABC or UVW.

[0395] The SSCD feedback signal may include, for example, the sensed voltage and / or current of the SSCD 1120. For example, the SSCD feedback signal may include the voltage level Vc across the capacitor C and / or the current I through the inductor L. L may include:

[0396] In this example, the module feedback signal is, for example, OC A ~OC W The operational characteristics may include one or more operational characteristics of each array 700-A through 700-W, designated as: As described above, the operational characteristics may include, for example, a combined SOC, SOH, temperature, voltage, current, SOP, and / or SOE of the arrays 700-A through 700-W.

[0397] Processing the control information may include adjusting the control information, e.g., adjusting a modulation index for one or more phases and / or a modulation reference signal for one or more phases. The SSCD controller 1122 may adjust the control information to adjust the DC signal output by the SSCD 1120 to the auxiliary load(s) 301. For example, the SSCD controller 1122 may adjust the control information to adjust the voltage level and / or current level of the DC signal output to the DC power bus 1136.

[0398] To adjust the voltage level of the output DC signal, the SSCD controller 1122 adjusts the voltage level V across the capacitor C so that the voltage level of the output DC signal is equal to this voltage level. c, can be adjusted.

[0399] The SSCD controller 1122 adjusts the external control information for one or both of the subpacks ABC and UVW to control the V c to increase or decrease the amount of energy being transferred from module pack 1110 to capacitor C. For example, if the voltage level of the output DC signal is lower than the reference voltage of the output DC signal, SSCD controller 1122 can adjust the external control information for subpacks A, B, C, and UVW to increase the amount of energy being transferred from module pack 1110 to capacitor C. If the voltage level of the output DC signal is higher than the reference voltage of the output DC signal, SSCD controller 1122 can adjust the external control information for subpacks A, B, C, and UVW to decrease the amount of energy being transferred from module pack 1110 to capacitor C. u and C l This can reduce the amount of energy being transferred to the

[0400] If the SSCD controller 1122 decides to adjust the external control information for one or both of subpacks ABC and UVW to increase or decrease the amount of energy being transferred to capacitor C, the SSCD controller 122 may adjust the modulation index and / or modulated reference signal in the same manner for all three phases of the subpack(s), for example, by increasing or decreasing the value by the same amount, or in different manners for balancing purposes.

[0401] 14F, SSCD controller 1122 can also perform multi-phase balancing techniques to balance one or more combined operating characteristics of subpacks A, B, C, and one or more combined operating characteristics of subpacks U, V, and W. To achieve this balancing without affecting the operation of motors 101-1 and 101-2, SSCD controller 1122 can be configured to make the same adjustments to the control information for each phase of subpacks A, B, C, or U, V, and W, adjusting the common-mode voltage of the AC signals supplied to motor 101-1 or motor 101-2.

[0402] The SSCD controller 1122 provides the processed control information to the control system 102 of the module pack 1110. As described above, the control system 102 may include one or more MCDs 112, LCDs 114, and an array controller 900 for each array 700, or a controller 950 for multiple arrays 700, e.g., a controller 950 for all arrays 700 in the module pack 1110, or a controller 950 for each segment. In this embodiment, the control system 102 may include an array controller 900 for each array 700-A through 700-W.

[0403] An array controller 900 for an array 700 can perform intra-phase balancing techniques to balance one or more operating characteristics of the modules 108 in the array 700. The controller 900 for an array 700 can receive processed control information for that array 700 (e.g., a processed modulation index for that array 700) and generate a modulation index for each module 108 of the array 700, as described herein, based on the processed control information and one or more operating characteristics of each module in the array 700. For example, the controller 900 for array 700-A can receive the processed modulation index for array 700-A and adjust the processed modulation index for each module 108 in array 700-A to balance one or more operating characteristics of the modules 108 in the array 700-A.

[0404] As described herein, MCD 112 can provide modulation indices and reference signals, or modulated reference signals, for modules 108 of array 700 to LCD 114, which controls modules 108 to generate the AC signals output by array 700, where the AC signals generated by arrays 700-A through 700-C are supplied to motor 101-1 and the AC signals generated by arrays 700-U through 700-W are supplied to motor 101-2.

[0405] Furthermore, the AC signals generated by arrays 700-A through 700-C and the AC signals generated by arrays 700-U through 700-W are supplied to SSCD 1120 via cable 1134. SSCD 1120 converts the AC signals to DC signals and outputs the DC signals to DC power bus 1136 to power auxiliary load 301.

[0406] The control system 102 and / or SSCD controller 1122 can be configured to control charging of the energy sources 206 of the modules 108 of the module pack 1110 while supplying DC power to the auxiliary load(s) 301 in both single-motor and two-motor embodiments.

[0407] Figures 15J and 15K illustrate example techniques for controlling components of the example embodiment of system 100 shown in Figures 15A-15C for charging energy source 206 in both single and dual motor embodiments. Figure 15J illustrates an example of an equivalent rectifier circuit 1580 during charging in single and dual motor embodiments. Figure 15K illustrates an example of an equivalent module pack configuration 1584 during charging in single and dual motor embodiments.

[0408] In this example, the equivalent circuit is the same for single motor charging and dual motor charging. Additionally, the equivalent rectifier circuit 1580 is the same as the equivalent rectifier circuit 1580 in Figures 15D and 15G.

[0409] To charge the energy sources 206 of the array 700 of module packs 1110, the control system 102 can couple the charging source 150 to the array 700 of module packs 1110 and route a charging signal to the energy sources 206 of the array 700. To do so, the control system 102 can open switches SA1, SB1, and SC1 to disconnect the module pack 1110 and charging source 150 from the motor 101-1. The control system 102 can also open switches SU1, SV1, and SW1 to disconnect the module pack 1110 and charging source 150 from either the motor 101-1 or the motor 101-2 (depending on whether the single-motor or two-motor embodiment is used).

[0410] Control system 102 may close switches SA2, SB2, SC2, SU2, SV2, and SW2 to allow a charging signal to reach arrays 700-A through 700-W from charging source 150. When DC charging is performed using DC charging source 150, control system 102 may close switches SCH2, SCH3, and SCH5 through SCH8 to couple DC charging source 150 to arrays 700-A through 700-W and SSCD 1120 via cable 1134 and ports A through C and U through W.

[0411] For DC charging, this switch configuration results in an equivalent rectifier circuit 1580 and equivalent module pack configuration 1584 where DC charging signals are provided to arrays 700-A through 700-W and diode segments DSU through DSW and DSA through DSC. Positive DC charging signals can be provided to arrays 700-A through 700-C, and negative DC charging signals can be provided to arrays 700-U through 700-W.

[0412] During charging, the SSCD controller 1122 can be bypassed because the DC voltage naturally consists of the DC charging signal coupled to the SSCD 1120. A positive DC charging signal is sent through ports A through C of connector 1310-1 to diode segments DA through DC, and a negative DC charging signal is sent through ports U through W of the connector to diode segments DU through DW. The DC charging signal charges capacitor C to the DC charging signal. The output DC signal of SSCD 1120 provided to DC power bus 1136 can be the same as the DC charging signal.

[0413] 16 is a flow diagram illustrating an example embodiment of a method 1600 for supplying power to one or more primary load(s) 101 and one or more auxiliary loads 301. The method 1600 may be performed by any embodiment of a system 100 having a module pack 1110 and an SSCD 1120 described herein. Each primary load 101 may be an AC load powered by an AC signal, and each auxiliary load 301 may be a DC load powered by a DC signal.

[0414] In step 1610, the SSCD controller 1122 receives control information. The SSCD controller 1122 may receive the control information from an external controller 104, such as from the motor controller 104. The control information may include, for example, a modulation index for each phase of the AC signal being supplied to the load(s) 101, a modulated reference signal for each phase, or a modulation index and a reference signal for each phase, or other control information.

[0415] In step 1620, the SSCD controller 1122 receives feedback signals. The SSCD controller 1122 may receive feedback signals from the SSCD 1120 and / or the module pack 1110. The feedback signals received from the SSCD 1120 may feed back signals related to the DC signals being supplied to the load(s) 301. For example, these feedback signals may include one or more capacitor voltage measurements across one or more capacitors of the SSCD 1120 and / or one or more current measurements along one or more DC lines of the SSCD 1120. The capacitor voltage measurements may be measured by V c,u and V c,l (e.g., in the embodiments of Figures 13A-14K) or V c (e.g., in the embodiments of Figures 15A-15K). The current measurements can be L,u and I L,l (e.g., in the embodiments of Figures 13A-14K) or I L (eg, in the embodiments of Figures 15A-15K).

[0416] The feedback signals from the module pack 1110 may include operational characteristics of the modules 108, the arrays 700-A through 700-W, and / or sub-packs of the array 700 (e.g., polyphase sub-packs A, B, C, and U, V, and W, and / or segment sub-packs A, B, V, and C, respectively). The operational characteristics may include, for example, the SOC, SOH, temperature, voltage, current, SOP, and / or SOE of each module 108, array 700-A through 700-W, and / or sub-pack. As described herein, the operational characteristics for the arrays 700-A through 700-W and sub-packs may include summations of the operational characteristics.

[0417] The level of summation and / or type of operational characteristic may differ for different embodiments and may vary based on the type (if any) of balancing technique used in those embodiments. For example, the module feedback signal in some embodiments may include a summation of subpacks A, B, C, and V, and W. In some embodiments, the module feedback signal may include a summation of some or all of arrays 700-A through 700-W in module pack 1110. In some embodiments, the module feedback signal may include values ​​of operational characteristics of individual modules 108 in module pack 1110. SSCD controller 1122 may be configured to aggregate values ​​as appropriate for the balancing technique performed by SSCD controller 1122.

[0418] In step 1630, the SSCD controller 1122 generates processed control information based on the feedback signal. The SSCD controller 1122 may generate the processed control information for adjusting the DC signal output by the SSCD 1120. In some embodiments, the SSCD controller 1122 may also generate processed control information for balancing one or more operating characteristics of the modules 108, the arrays 700-A through 700-W, and / or the subpacks (e.g., the polyphase subpacks A, B, C, and U, and / or the segment subpacks A, B, and C).

[0419] To adjust the output DC signal, the SSCD controller 1122 can compare the voltage measurement(s) received from the SSCD with corresponding reference value(s). The reference value(s) can be based on a target voltage level for the output DC signal. For example, the SSCD controller 1122 can adjust the voltage V c,u and V c,l and / or the voltage V c,u and V c,lThe sum of may be compared to a reference value. If the reference value is higher than the measurement, the SSCD controller 1122 may adjust the control information to cause the module pack 1110 to increase the amount of energy output from the module pack 1110 to the SSCD 1120, for example, by increasing the modulation index for one or more phases. If the reference value is lower than the measurement, the SSCD controller 1122 may adjust the control information to cause the module pack 1110 to decrease the amount of energy output from the module pack 1110 to the SSCD 1120, for example, by decreasing the modulation index for one or more phases.

[0420] The SSCD controller 1122 may be configured to perform one or more balancing techniques depending on the configuration of the module pack 1110 and / or the SSCD 120 and / or based on the number of load(s) 101 powered by the module pack 1110. In an embodiment having two loads 101-1 and 101-2, with subpack ABC supplying power to load 101-1 and subpack UVW supplying power to load 101-2, the SSCD controller 1122 may be configured to perform multi-phase subpack balancing to balance one or more operating characteristics between the multi-phase subpacks ABC and UVW.

[0421] In multi-phase subpack balancing, the SSCD controller 1122 can be configured to adjust the control information so that each array 700 in a multi-phase subpack outputs the same amount of additional energy or less energy to adjust the common-mode voltage of the AC signal provided by the arrays 700 within the subpack. In this manner, the amount of energy output to the SSCD 1120 is adjusted without adjusting the amount of energy output to the load 101. For example, if multi-phase subpacks A, B, C have a higher SOC than subpacks U, V, and W, the SSCD controller 1122 can decrease the energy output by multi-phase subpacks U, V, and W to the SSCD 1120 (e.g., by decreasing the modulation index for arrays 700-U through 700-W) and increase the amount of energy output by multi-phase subpacks A, B, and W to the SSCD 1120 (e.g., by decreasing the modulation index for arrays 700-U through 700-W). If the increase is equal across arrays 700-A to 700-B and the decrease is equal across arrays 700-U to 700-W, the power delivered to loads 101-1 and 101-2 can remain the same while shifting the energy source to SSCD 1120 and auxiliary load(s) 301.

[0422] In an embodiment having one load 101-1 powered in an open winding configuration such that both subpacks ABC and UVW supply power to the load 101-1, the SSCD controller 1122 may be configured to perform a multi-phase balancing technique (as described above) to balance one or more operating characteristics between the multi-phase subpacks ABC and UVW, and / or a segment subpack balancing technique to balance one or more operating characteristics between the segment subpacks AU, BV, and CW.

[0423] In segment subpack balancing, SSCD controller 1122 can adjust the amount of energy output by segment subpacks AU, BV, and / or CW to balance their operating characteristic(s). For example, if subpack CW has the highest temperature and AU has the lowest temperature, SSCD controller 1122 can adjust the control information for subpack CW to reduce (e.g., equally) the amount of energy output by arrays 700-C and 700-W and / or increase (e.g., equally) the amount of energy output by arrays 700-A and 700-U.

[0424] In both of these types of subpack balancing, the SSCD controller 1122 can adjust the subpack control information so that an appropriate amount of energy is supplied to the SSCD 1120 to regulate the output DC voltage of the SSCD 1120 for the auxiliary load(s) 301, but the amount of energy contributed by each subpack is different. For example, if the SSCD controller 1122 reduces the amount of energy output by one subpack, the SSCD controller 1122 can compensate for this reduction by increasing the amount of energy output by one or more other subpacks.

[0425] In step 1640, the control system 102 controls the modules 108 of the module pack 1110 based on the processed control information. The SSCD controller 1122 can provide the processed control information to one or more MCDs 112 of the control system 102. For example, the control system 102 can include an MCD 112 for the entire module pack 1110, an MCD 112 for each subpack A, B, C, and W (or segment subpacks A, B, and CW), or an MCD 112 for each array 700-A through 700-W. The SSCD controller 1122 can provide the appropriate processed control information to each MCD 112. The MCDs 112 can generate control information for the modules 108 controlled by the MCDs 112 based on the processed control information. For example, if there is an MCD 112 for each array 700-A through 700-W, the MCD 112 may receive the processed control information for that array 700 and generate control information for each module 108 in that array 700.

[0426] In some embodiments, the MCD 112 may generate control information using an intra-phase balancing technique to balance one or more operational characteristics of the modules 108 in the array 700 controlled by the MCD 112. For example, if the MCD 112 controls the modules 108 of the array 700-A, the MCD 112 may receive control information (e.g., modulation indexes or modulated reference signals) and generate individual modulation indexes or individual modulated reference signals for the modules 108 of the array 700-A based on the received control information and the operational characteristics of the modules 108 of the array 700-A.

[0427] In step 1650, the module pack 1110 outputs an AC signal to the load(s) 101. As described herein, the MCD 112 can provide control information to the LCD 114, which controls the converters 202 of the modules 108 to output energy based on the control information. Each array 700 can be configured to output an AC voltage signal that includes a superposition of the output voltages from the modules 108 of that array 700.

[0428] In step 1660, SSCD 1120 outputs a DC signal to auxiliary load(s) 301. SSCD 1120 may receive the AC signal output by arrays 700-A through 700-C and / or 700-U through 700-W and convert the AC signal to an output DC signal for auxiliary load(s) 301.

[0429] Considering and / or supplementing the previously described embodiments, various aspects of the present subject matter are described below, with emphasis placed on the interrelationship and compatibility of the following embodiments, in other words, on the fact that each feature of the embodiments can be combined with each other feature unless expressly stated or taught otherwise.

[0430] In many embodiments, a modular energy system controllable to power one or more AC loads and one or more DC loads includes a plurality of modules connected to a plurality of arrays arranged in a plurality of array segments, each array configured to output an AC voltage signal comprising a superposition of output voltages from the modules of that array, each array segment including a plurality of arrays coupled at a common point, the plurality of arrays coupled to power one or more AC loads, and an auxiliary signal conversion device coupled to the output of each array and configured to convert the AC voltage signal output by one or more of the plurality of arrays to an output DC signal and to supply the output DC signal to one or more DC loads.

[0431] In some embodiments, each module includes one or more energy sources and a converter including a switch circuit configured to generate the output voltage for the module.

[0432] In some embodiments, the one or more AC loads include one or more electric motors of an electric vehicle.

[0433] In some embodiments, the one or more DC loads include one or more auxiliary loads of the electric vehicle.

[0434] In some embodiments, the auxiliary signal conversion device includes a rectifier circuit.

[0435] In some embodiments, the rectifier circuit includes a plurality of diodes, and the outputs of one or more arrays are coupled to one or more of the plurality of diodes.

[0436] In some embodiments, the outputs of each array are coupled to respective diode pairs of the plurality of diodes.

[0437] In some embodiments, the output of one array in each segment is coupled to one or more diodes of the rectifier circuit.

[0438] In some embodiments, the outputs of the entire array of each segment are coupled to one or more diodes of the rectifier circuit.

[0439] In some embodiments, the output of each array is coupled to a respective diode pair coupled between the positive and negative DC lines of the auxiliary signal conversion device.

[0440] In some embodiments, the output of each array is coupled to the positive DC line via a first diode of the respective diode pair and to the negative DC line via a second diode of the respective diode pair.

[0441] In some embodiments, the rectifier circuit includes a filter circuit.

[0442] In some embodiments, the auxiliary signal conversion device includes a positive DC line, a negative DC line, and an intermediate DC line, and the rectifier circuit includes a first capacitor coupled between the positive DC line and the intermediate DC line, and a second capacitor coupled between the negative DC line and the intermediate DC line.

[0443] In some embodiments, the positive DC line is coupled to a positive line of a DC power bus coupled to the one or more DC loads, and the negative DC line is coupled to a negative line of the DC power bus.

[0444] In some embodiments, the auxiliary signal conversion device is configured to adjust a first voltage level across the first capacitor and a second voltage level across the second capacitor.

[0445] In some embodiments, the auxiliary signal conversion device includes a controller.

[0446] In some embodiments, the controller is configured to balance one or more operating characteristics of the plurality of modules.

[0447] In some embodiments, the controller is configured to balance one or more operating characteristics of the plurality of arrays.

[0448] In some embodiments, the controller is configured to balance one or more operating characteristics of two or more sub-packs each comprising two or more arrays of the plurality of arrays.

[0449] In some embodiments, each segment is a subpack.

[0450] In some embodiments, the one or more AC loads include one or more electric motors of an electric vehicle, and the controller is configured to receive control information from a motor controller configured to generate control information for controlling one or more operating characteristics of one of the one or more electric motors, and to adjust the received control information to generate processed control information based on one or more feedback signals of the auxiliary signal conversion device.

[0451] In some embodiments, the one or more feedback signals include a voltage level of one or more capacitors of the auxiliary signal conversion device.

[0452] In some embodiments, the control information includes one or more modulation indices.

[0453] In some embodiments, the one or more modulation indices include a modulation index for each of a plurality of phases.

[0454] In some embodiments, the one or more AC loads include a three-phase motor, and the one or more modulation indices include a modulation index for each of its three phases.

[0455] In some embodiments, the controller is configured to generate the processed control information based on (i) one or more operational characteristics of each module of the plurality of modules, (ii) one or more operational characteristics of each array of the plurality of arrays, or (iii) one or more operational characteristics of each subpack of an array.

[0456] In some embodiments, the one or more operational characteristics of each module include at least one of a state of charge of the module or a temperature of the module.

[0457] In some embodiments, the one or more operating characteristics of each array include at least one of an aggregated state of charge of the array or an aggregated temperature of the array.

[0458] In some embodiments, the one or more operating characteristics of each sub-pack include at least one of a combined state of charge of the sub-pack or a combined temperature of the sub-pack.

[0459] In some embodiments, the controller is configured to balance the one or more operating characteristics by adjusting the control information.

[0460] In some embodiments, the auxiliary signal conversion device includes a positive DC line and a negative DC line, and the rectifier circuit may include a capacitor coupled between the positive DC line and the negative DC line.

[0461] In some embodiments, the positive DC line is coupled to a positive line of a DC power bus coupled to the one or more DC loads, and the negative DC line is coupled to a negative line of the DC power bus, and the auxiliary signal conversion device is configured to adjust a voltage level across the capacitor.

[0462] In some embodiments, the rectifier circuit includes a plurality of diode segments, including a respective diode segment for each array segment of the plurality of array segments, the respective diode segment for each array segment including: (i) a first diode coupled between an output of the array segment and a positive DC line of the rectifier circuit; and (ii) a second diode coupled between the output of the array segment and a negative DC line of the rectifier circuit. The rectifier circuit can include a filter circuit and a local controller, the filter circuit coupled to the positive DC line and the negative DC line and including a DC-coupled output coupled to the one or more DC loads, the local controller configured to obtain one or more feedback signals of the SSCD and provide the feedback signals to an SSCD controller configured to adjust control information for the array of the array segments based on the feedback signals.

[0463] In some embodiments, the rectifier circuit further comprises an intermediate DC line.

[0464] In some embodiments, the neutral point of each array segment is coupled to the intermediate DC line.

[0465] In some embodiments, a phase port of at least one of each of the plurality of arrays is coupled to the intermediate DC line.

[0466] In some embodiments, the phase port of each array of subpacks of the array is coupled to the intermediate DC line.

[0467] In some embodiments, the plurality of diode segments includes a diode segment having a first diode coupled between the positive DC line and the intermediate DC line and a second diode coupled between the intermediate DC line and the negative DC line.

[0468] In some embodiments, the first diode of each diode segment is configured to transmit a positive current to the positive DC line and the second diode of each segment is configured to transmit a negative current to the negative DC line.

[0469] In some embodiments, the one or more AC loads include one or more polyphase loads, and the plurality of arrays includes at least one array for each phase of the one or more polyphase loads.

[0470] In some embodiments, each segment includes an array pair for a single phase, and each array pair includes a first array and a second array.

[0471] In some embodiments, the common point of each segment is a common neutral point of the segment, and the neutral point of the first array is coupled to the neutral point of the second array at the common neutral point of the segment.

[0472] In some embodiments, the common neutral point of each segment is coupled to the common neutral point of each other segment.

[0473] In some embodiments, the one or more AC loads include two electric vehicle motors.

[0474] In some embodiments, the common neutral point of each segment is coupled to a respective neutral terminal of a connector on a cable connecting the output of each array to the rectifying circuitry of the auxiliary signal converter.

[0475] In some embodiments, the connector includes a respective port for each output of each array.

[0476] In some embodiments, the one or more AC loads include a single electric vehicle motor, and the neutral point of the first array is coupled to the neutral point of the second array of each segment without coupling the common neutral point of each segment to the common neutral point of each other segment.

[0477] In some embodiments, the system includes a first switch configured to selectively couple a common neutral point of a first pair of arrays for a first phase to a common neutral point of a second pair of arrays for a second phase. The system can include a second switch configured to selectively couple a common neutral point of a second pair of arrays for a second phase to a common neutral point of a third pair of arrays for a third phase.

[0478] In many embodiments, a modular energy system includes a module pack including multiple segments of an array of modules, each segment of the array including multiple coupled arrays, each segment of the array configured to output an AC voltage signal having the same phase angle, the phase angle of the AC signal output by each segment of the array being different from the phase angle of the AC signal output by each other array. The system includes a rectifier circuit configured to convert the AC voltage signal output by each segment to a DC signal for one or more auxiliary loads. The system includes a control system configured to control the modules of each array and adjust the DC signal to balance one or more operating characteristics of the modules of the array.

[0479] In many embodiments, a method for powering one or more AC loads and one or more DC loads includes powering the one or more AC loads with a plurality of modules connected to a plurality of arrays arranged in a plurality of array segments, each array configured to output an AC voltage signal including a superposition of output voltages from the modules of that array, each array segment including a plurality of arrays coupled at a common point, converting the AC voltage signal output by one or more of the plurality of arrays into an output DC signal by an auxiliary signal converter coupled to an output of each array, and providing the output DC signal to the one or more DC loads.

[0480] In some embodiments, each module includes one or more energy sources and a converter including a switch circuit configured to generate the output voltage for the module.

[0481] In some embodiments, the one or more AC loads include one or more electric motors of an electric vehicle.

[0482] In some embodiments, the one or more DC loads include one or more auxiliary loads of the electric vehicle.

[0483] In some embodiments, the auxiliary signal conversion device includes a rectifier circuit.

[0484] In some embodiments, the rectifier circuit includes a plurality of diodes, and the outputs of one or more arrays are coupled to one or more of the plurality of diodes.

[0485] In some embodiments, the outputs of each array are coupled to respective diode pairs of the plurality of diodes.

[0486] In some embodiments, the output of one array in each segment is coupled to one or more diodes of the rectifier circuit.

[0487] In some embodiments, the outputs of the entire array of each segment are coupled to one or more diodes of the rectifier circuit.

[0488] In some embodiments, the output of each array is coupled to a respective diode pair coupled between the positive and negative DC lines of the auxiliary signal conversion device.

[0489] In some embodiments, the output of each array is coupled to the positive DC line via a first diode of the respective diode pair and to the negative DC line via a second diode of the respective diode pair.

[0490] In some embodiments, the rectifier circuit includes a filter circuit.

[0491] In some embodiments, the auxiliary signal conversion device includes a positive DC line, a negative DC line, and an intermediate DC line, and the rectifier circuit includes a first capacitor coupled between the positive DC line and the intermediate DC line, and a second capacitor coupled between the negative DC line and the intermediate DC line.

[0492] In some embodiments, the positive DC line is coupled to a positive line of a DC power bus coupled to the one or more DC loads, and the negative DC line is coupled to a negative line of the DC power bus.

[0493] In some embodiments, the auxiliary signal conversion device is configured to adjust a first voltage level across the first capacitor and a second voltage level across the second capacitor.

[0494] In some embodiments, the auxiliary signal conversion device includes a controller.

[0495] In some embodiments, the controller is configured to balance one or more operating characteristics of the plurality of modules.

[0496] In some embodiments, the controller is configured to balance one or more operating characteristics of the plurality of arrays.

[0497] In some embodiments, the controller is configured to balance one or more operating characteristics of two or more sub-packs each comprising two or more arrays of the plurality of arrays.

[0498] In some embodiments, each segment is a subpack.

[0499] In some embodiments, the one or more AC loads include one or more electric motors of an electric vehicle, and the controller receives control information from a motor controller configured to generate control information for controlling one or more operating characteristics of one of the one or more electric motors, and adjusts the received control information to generate processed control information based on one or more feedback signals of the auxiliary signal conversion device.

[0500] In some embodiments, the one or more feedback signals include a voltage level of one or more capacitors of the auxiliary signal conversion device.

[0501] In some embodiments, the control information includes one or more modulation indices.

[0502] In some embodiments, the one or more modulation indices include a modulation index for each of a plurality of phases.

[0503] In some embodiments, the one or more AC loads include a three-phase motor, and the one or more modulation indices include a modulation index for each of its three phases.

[0504] In some embodiments, the method includes generating, by the controller, the processed control information based on (i) one or more operational characteristics of each module of the plurality of modules, (ii) one or more operational characteristics of each array of the plurality of arrays, or (iii) one or more operational characteristics of each subpack of an array.

[0505] In some embodiments, the one or more operational characteristics of each module include at least one of a state of charge of the module or a temperature of the module.

[0506] In some embodiments, the one or more operating characteristics of each array include at least one of an aggregated state of charge of the array or an aggregated temperature of the array.

[0507] In some embodiments, the one or more operating characteristics of each sub-pack include at least one of a combined state of charge of the sub-pack or a combined temperature of the sub-pack.

[0508] In some embodiments, the controller is configured to balance the one or more operating characteristics by adjusting the control information.

[0509] In some embodiments, the auxiliary signal conversion device includes a positive DC line and a negative DC line, and the rectifier circuit includes a capacitor coupled between the positive DC line and the negative DC line.

[0510] In some embodiments, the positive DC line is coupled to a positive line of a DC power bus coupled to the one or more DC loads, and the negative DC line is coupled to a negative line of the DC power bus, and the auxiliary signal conversion device is configured to adjust a voltage level across the capacitor.

[0511] In some embodiments, the rectifier circuit includes a plurality of diode segments, including a respective diode segment for each array segment of the plurality of array segments, the respective diode segment for each array segment including (i) a first diode coupled between an output of the array segment and a positive DC line of the rectifier circuit, and (ii) a second diode coupled between the output of the array segment and a negative DC line of the rectifier circuit. The rectifier circuit includes a filter circuit, the filter circuit coupled to the positive DC line and the negative DC line, and including a DC-coupled output coupled to the one or more DC loads. The rectifier circuit includes a local controller configured to obtain one or more feedback signals of the SSCD and provide the feedback signals to an SSCD controller configured to adjust control information for the array of the array segments based on the feedback signals.

[0512] In some embodiments, the rectifier circuit includes an intermediate DC line.

[0513] In some embodiments, the neutral point of each array segment is coupled to the intermediate DC line.

[0514] In some embodiments, a phase port of at least one of each of the plurality of arrays is coupled to the intermediate DC line.

[0515] In some embodiments, the phase port of each array of subpacks of the array is coupled to the intermediate DC line.

[0516] In some embodiments, the plurality of diode segments includes a diode segment having a first diode coupled between the positive DC line and the intermediate DC line and a second diode coupled between the intermediate DC line and the negative DC line.

[0517] In some embodiments, the first diode of each diode segment is configured to transmit a positive current to the positive DC line and the second diode of each segment is configured to transmit a negative current to the negative DC line.

[0518] In some embodiments, the one or more AC loads include one or more polyphase loads, and the plurality of arrays includes at least one array for each phase of the one or more polyphase loads.

[0519] In some embodiments, each segment includes an array pair for a single phase, and each array pair includes a first array and a second array.

[0520] In some embodiments, the common point of each segment is a common neutral point of the segment, and the neutral point of the first array is coupled to the neutral point of the second array at the common neutral point of the segment.

[0521] In some embodiments, the common neutral point of each segment is coupled to the common neutral point of each other segment.

[0522] In some embodiments, the one or more AC loads include two electric vehicle motors.

[0523] In some embodiments, the common neutral point of each segment is coupled to a respective neutral terminal of a connector on a cable connecting the output of each array to the rectifying circuitry of the auxiliary signal converter.

[0524] In some embodiments, the connector includes a respective port for each output of each array.

[0525] In some embodiments, the one or more AC loads include a single electric vehicle motor, and the neutral point of the first array is coupled to the neutral point of the second array of each segment without coupling the common neutral point of each segment to the common neutral point of each other segment.

[0526] In some embodiments, the method includes selectively coupling, by a first switch, a common neutral point of a first pair of arrays for a first phase to a common neutral point of a second pair of arrays for a second phase, and selectively coupling, by a second switch, a common neutral point of the second pair of arrays for the second phase to a common neutral point of a third pair of arrays for a third phase.

[0527] In many embodiments, a modular energy system includes a module pack including multiple segments of an array of modules, each segment of the array including multiple coupled arrays, each segment of the array configured to output an AC voltage signal having the same phase angle, the phase angle of the AC signal output by each segment of the array being different from the phase angle of the AC signal output by each other array. The energy system includes a rectifier circuit configured to convert the AC voltage signal output by each segment to a DC signal for one or more auxiliary loads. The energy system includes a control system configured to control the modules of each array and adjust the DC signal to balance one or more operating characteristics of the modules of the array.

[0528] In some embodiments, the control system is configured to receive control information from an external device and adjust the control information to condition the DC signal to balance the one or more operating characteristics.

[0529] In some embodiments, the control information includes a modulation index for each segment of the array.

[0530] In some embodiments, the operating characteristics include at least one of a state of charge or a temperature for each module.

[0531] In some embodiments, the operating characteristics include at least one of a state of charge or a temperature for each array.

[0532] In some embodiments, the operating characteristics include at least one of a state of charge or a temperature of each segment.

[0533] In some embodiments, the module pack is configured to supply the AC signals output by each array to one or more electric motors.

[0534] In some embodiments, the one or more electric motors include open winding motors.

[0535] In some embodiments, the control system is configured to adjust a modulation index for at least one segment to balance the one or more operating characteristics of the modules of the array.

[0536] In many embodiments, a module pack includes a first segment of an array, a second segment of an array, a third segment of an array, a first set of ports, and a second set of ports, wherein the first segment of the array includes (i) a first array of first modules configured to output a first AC voltage signal having a first phase angle, the first AC voltage signal comprising a superposition of output voltages from the first modules, and (ii) a second array of second modules configured to output a second AC voltage signal having the first phase angle, the second AC voltage signal comprising a superposition of output voltages from the second modules, wherein a first neutral point of the first array is coupled to a second neutral point of the second array. The second segment includes: (i) a third array of third modules configured to output a third AC voltage signal having a second phase angle, the third AC voltage signal including a superposition of output voltages from the third modules; and (ii) a fourth array of fourth modules configured to output a fourth AC voltage signal having the second phase angle, the fourth AC voltage signal including a superposition of output voltages from the fourth modules, wherein a third neutral point of the third array is coupled to a fourth neutral point of the fourth array. The third segment includes (i) a fifth array of fifth modules configured to output a fifth AC voltage signal having a third phase angle, the fifth AC voltage signal including a superposition of output voltages from the fifth modules, and (ii) a sixth array of sixth modules configured to output a sixth AC voltage signal having the third phase angle, the sixth AC voltage signal including a superposition of output voltages from the sixth modules, wherein a fifth neutral point of the fifth array is coupled to a sixth neutral point of the sixth array. The first set of ports is for coupling each phase output of at least one array of each segment to one or more three-phase loads.The second set of ports is for coupling at least one array of each segment to a rectifier circuit configured to convert the AC voltage signal to a DC signal for powering one or more auxiliary loads.

[0537] In many embodiments, the rectifier circuit includes a positive DC line, an intermediate DC line, a negative DC line, and a diode circuit including a set of diode segments each including two diodes coupled between the positive DC line and the negative DC line, and the rectifier circuit includes a filter circuit including an inductor disposed along the positive DC line, a first capacitor coupled between the positive DC line and the intermediate DC line, and a second capacitor coupled between the intermediate DC line and the negative DC line.

[0538] In many embodiments, a phase output of the array of modules is coupled between the two diodes of at least a subset of the diode segments.

[0539] In many embodiments, the cable includes a first connector at a first end and a second connector at a second end of the cable. The first connector includes a plurality of first ports configured to mate with a module pack including a first plurality of arrays of modules and a second plurality of arrays of modules. The plurality of first ports includes a respective port for each array and one or more first neutral ports for one or more corresponding neutral points of the arrays. The second connector includes a plurality of second ports corresponding to the plurality of first ports. The second connector is configured to connect to the rectifier circuit in a first orientation for electric vehicles having a single motor and in a second orientation different from the first orientation for electric vehicles having two motors.

[0540] The term "module" as used herein refers to one of two or more devices or subsystems within a larger system. The module can be configured to work with other modules having similar size, functionality, and physical arrangement (e.g., electrical terminal, connector location, etc.). Modules having the same functionality and energy source(s) can be configured identically (e.g., size and physical arrangement) to all other modules in the same sys...

Claims

1. 1. A modular energy system controllable to supply power to one or more AC loads and one or more DC loads, comprising: a plurality of modules connected to a plurality of arrays arranged in a plurality of array segments, each array configured to output an AC voltage signal comprising a superposition of output voltages from the modules of that array, each array segment including a plurality of arrays coupled at a common point, the plurality of arrays coupled to supply power to one or more AC loads; an auxiliary signal conversion device coupled to the output of each array and configured to convert an AC voltage signal output by one or more of the plurality of arrays into an output DC signal and provide the output DC signal to supply one or more DC loads.

2. The system of claim 1 , wherein each module includes one or more energy sources and a converter including a switch circuit configured to generate the output voltage for the module.

3. 3. The system of claim 1 or 2, wherein the one or more AC loads include one or more electric motors of an electric vehicle.

4. The system of claim 3 , wherein the one or more DC loads include one or more auxiliary loads of the electric vehicle.

5. 10. A system according to any preceding claim, wherein the auxiliary signal conversion device comprises a rectifier circuit.

6. The system of claim 5 , wherein the rectifier circuit includes a plurality of diodes, and the output of one or more arrays is coupled to one or more of the plurality of diodes.

7. The system of claim 6 , wherein the output of each array is coupled to a respective diode pair of the plurality of diodes.

8. 8. A system according to claim 5, wherein the output of one array of each segment is coupled to one or more diodes of the rectifier circuit.

9. 9. The system of claim 5, wherein the outputs of all arrays in each segment are coupled to one or more diodes in the rectifier circuit.

10. 8. The system of claim 7, wherein the output of each array is coupled to a respective diode pair coupled between a positive DC line and a negative DC line of the auxiliary signal converter.

11. 10. The system of claim 9, wherein the output of each array is coupled to the positive DC line through a first diode of the respective diode pair and to the negative DC line through a second diode of the respective diode pair.

12. The system of claim 5 , wherein the rectifier circuit includes a filter circuit.

13. 13. The system of claim 12, wherein the auxiliary signal conversion device includes a positive DC line, a negative DC line, and an intermediate DC line, and the rectifier circuit includes a first capacitor coupled between the positive DC line and the intermediate DC line and a second capacitor coupled between the negative DC line and the intermediate DC line.

14. 14. The system of claim 13, wherein the positive DC line is coupled to a positive line of a DC power bus coupled to the one or more DC loads and the negative DC line is coupled to a negative line of the DC power bus.

15. 15. The system of claim 14, wherein the auxiliary signal conversion device is configured to adjust a first voltage level across the first capacitor and a second voltage level across the second capacitor.

16. The system of claim 15 , wherein the auxiliary signal conversion device includes a control device.

17. The system of claim 16 , wherein the controller is configured to balance one or more operating characteristics of the plurality of modules.

18. 18. The system of claim 16, wherein the controller is configured to balance one or more operating characteristics of the plurality of arrays.

19. 19. The system of any one of claims 16 to 18, wherein the controller is configured to balance one or more operating characteristics of two or more sub-packs each comprising two or more arrays of the plurality of arrays.

20. 20. The system of claim 19, wherein each segment is a subpack.

21. the one or more AC loads include one or more electric motors of an electric vehicle, and the controller: receiving control information from a motor controller configured to generate control information for controlling one or more operating characteristics of one of the one or more electric motors; 21. A system according to any one of claims 16 to 20, wherein the received control information is adjusted to generate processed control information based on one or more feedback signals of the auxiliary signal conversion device.

22. 22. The system of claim 21, wherein the one or more feedback signals include a voltage level of one or more capacitors of the auxiliary signal conversion device.

23. 23. The system of claim 21 or 22, wherein the control information comprises one or more modulation indices.

24. 24. The system of claim 23, wherein the one or more modulation indices include a modulation index for each of a plurality of phases.

25. 24. The system of claim 23, wherein the one or more AC loads include a three-phase motor, and the one or more modulation indices include a modulation index for each of its three phases.

26. 26. The system of claim 21, wherein the controller is configured to generate the processed control information based on (i) one or more operational characteristics of each module of the plurality of modules, (ii) one or more operational characteristics of each array of the plurality of arrays, or (iii) one or more operational characteristics of each sub-pack of an array.

27. 27. The system of claim 26, wherein the one or more operational characteristics of each module include at least one of a state of charge of the module or a temperature of the module.

28. 28. The system of claim 26 or 27, wherein the one or more operating characteristics of each array include at least one of an aggregated state of charge of the array or an aggregated temperature of the array.

29. 29. The system of any one of claims 26 to 28, wherein the one or more operational characteristics of each sub-pack include at least one of a combined state of charge of the sub-pack or a combined temperature of the sub-pack.

30. 30. The system of any one of claims 26 to 29, wherein the controller is configured to balance the one or more operating characteristics by adjusting the control information.

31. 13. The system of claim 12, wherein the auxiliary signal conversion device includes a positive DC line and a negative DC line, and the rectifier circuit includes a capacitor coupled between the positive DC line and the negative DC line.

32. 32. The method of claim 31 , wherein the positive DC line is coupled to a positive line of a DC power bus coupled to the one or more DC loads and the negative DC line is coupled to a negative line of the DC power bus, and the auxiliary signal conversion device is configured to adjust a voltage level across the capacitor.

33. The rectifier circuit a plurality of diode segments including a respective diode segment for each array segment of the plurality of array segments, the respective diode segment for each array segment including: (i) a first diode coupled between an output of the array segment and a positive DC line of the rectifier circuit; and (ii) a second diode coupled between the output of the array segment and a negative DC line of the rectifier circuit; a filter circuit coupled to the positive DC rail and the negative DC rail and including a DC coupled output coupled to the one or more DC loads; a local controller configured to obtain one or more feedback signals for the SSCD and provide the feedback signals to an SSCD controller configured to adjust control information for the array of the array segments based on the feedback signals.

34. 34. The system of claim 33, wherein the rectifier circuit further comprises an intermediate DC line.

35. 35. The system of claim 34, wherein a neutral point of each array segment is coupled to the intermediate DC line.

36. 35. The system of claim 34, wherein a phase port of at least one of each of the plurality of arrays is coupled to the intermediate DC line.

37. 37. The system of claim 36, wherein a phase port of each array of subpacks of the array is coupled to the intermediate DC line.

38. 38. The system of claim 34, wherein the plurality of diode segments includes a diode segment having a first diode coupled between the positive DC line and the intermediate DC line and a second diode coupled between the intermediate DC line and the negative DC line.

39. 39. The system of any one of claims 34 to 38, wherein the first diode of each diode segment is configured to conduct a positive current to the positive DC rail and the second diode of each segment is configured to conduct a negative current to the negative DC rail.

40. 10. The system of any preceding claim, wherein the one or more AC loads include one or more polyphase loads, and the plurality of arrays includes at least one array for each phase of the one or more polyphase loads.

41. 41. The system of claim 40, wherein each segment includes an array pair for a single phase, each array pair including a first array and a second array.

42. 42. The method of claim 41 , wherein a common point of each segment is a common neutral point of the segment, and wherein a neutral point of the first array is coupled to a neutral point of the second array at the common neutral point of the segment.

43. 43. The system of claim 42, wherein the common neutral point of each segment is coupled to the common neutral point of each other segment.

44. 44. The system of claim 43, wherein the one or more AC loads include two electric vehicle motors.

45. 45. A system as claimed in claim 43 or 44, wherein the common neutral point of each segment is coupled to a respective neutral terminal of a connector of a cable connecting the output of each array to a rectifying circuit of the auxiliary signal conversion device.

46. 46. ​​The system of claim 45, wherein the connector includes a respective port for each output of each array.

47. 42. The method of claim 41 , wherein the one or more AC loads include a single electric vehicle motor, and the neutral point of the first array is coupled to the neutral point of the second array of each segment without coupling the common neutral point of each segment to the common neutral point of each other segment.

48. a first switch configured to selectively couple a common neutral point of a first pair of arrays for a first phase to a common neutral point of a second pair of arrays for a second phase; 42. The system of claim 41, further comprising: a second switch configured to selectively couple the common neutral point of the second pair of arrays for the second phase to a common neutral point of a third pair of arrays for a third phase.

49. a module pack including a plurality of segments of an array of modules, each segment of the array including a plurality of coupled arrays, each segment of the array configured to output an AC voltage signal having the same phase angle, the phase angle of the AC signal output by each segment of the array being different from the phase angle of the AC signal output by each other array; a rectifier circuit configured to convert the AC voltage signal output by each segment into a DC signal for one or more auxiliary loads; a control system configured to control the modules of each array to adjust the DC signal to balance one or more operating characteristics of the modules of the array.

50. 1. A method for powering one or more AC loads and one or more DC loads, comprising: powering the one or more AC loads with a plurality of modules connected to a plurality of arrays arranged in a plurality of array segments, each array configured to output an AC voltage signal comprising a superposition of output voltages from the modules of that array, each array segment comprising a plurality of arrays coupled at a common point; converting, by an auxiliary signal conversion device coupled to the output of each array, the AC voltage signals output by one or more of the plurality of arrays into output DC signals; and providing the output DC signal to the one or more DC loads.

51. 51. The method of claim 50, wherein each module includes one or more energy sources and a converter including a switch circuit configured to generate the output voltage for the module.

52. 52. The method of claim 50 or 51, wherein the one or more AC loads include one or more electric motors of an electric vehicle.

53. 53. The method of claim 52, wherein the one or more DC loads include one or more auxiliary loads of the electric vehicle.

54. 54. The method of any one of claims 50 to 53, wherein the auxiliary signal conversion device includes a rectifier circuit.

55. 55. The method of claim 54, wherein the rectifier circuit includes a plurality of diodes, and the output of one or more arrays is coupled to one or more of the plurality of diodes.

56. 56. The method of claim 55, wherein the output of each array is coupled to a respective diode pair of the plurality of diodes.

57. 57. The method of any of claims 54 to 56, wherein the output of one array of each segment is coupled to one or more diodes of the rectifier circuit.

58. 58. The method of any one of claims 55 to 57, wherein the outputs of the entire array of each segment are coupled to one or more diodes of the rectifier circuit.

59. 57. The method of claim 56, wherein the output of each array is coupled to a respective diode pair coupled between a positive DC line and a negative DC line of the auxiliary signal conversion device.

60. 59. The method of claim 58, wherein the output of each array is coupled to the positive DC line through a first diode of the respective diode pair and to the negative DC line through a second diode of the respective diode pair.

61. 61. The method of any one of claims 54 to 60, wherein the rectifier circuit includes a filter circuit.

62. 62. The method of claim 61, wherein the auxiliary signal conversion device includes a positive DC line, a negative DC line, and an intermediate DC line, and the rectifier circuit includes a first capacitor coupled between the positive DC line and the intermediate DC line and a second capacitor coupled between the negative DC line and the intermediate DC line.

63. 63. The method of claim 62, wherein the positive DC line is coupled to a positive line of a DC power bus coupled to the one or more DC loads and the negative DC line is coupled to a negative line of the DC power bus.

64. 64. The method of claim 63, wherein the auxiliary signal conversion device is configured to adjust a first voltage level across the first capacitor and a second voltage level across the second capacitor.

65. 65. The method of claim 64, wherein the auxiliary signal conversion device comprises a control device.

66. 66. The method of claim 65, wherein the controller is configured to balance one or more operating characteristics of the plurality of modules.

67. 67. The method of any one of claims 65 to 66, wherein the controller is configured to balance one or more operating characteristics of the plurality of arrays.

68. 68. The method of any one of claims 65 to 67, wherein the controller is configured to balance one or more operating characteristics of two or more sub-packs each comprising two or more arrays of the plurality of arrays.

69. 69. The method of claim 68, wherein each segment is a subpack.

70. the one or more AC loads include one or more electric motors of an electric vehicle, and the controller: receiving control information from a motor controller configured to generate control information for controlling one or more operating characteristics of one of the one or more electric motors; 70. A method according to any one of claims 65 to 69, further comprising adjusting the received control information to generate processed control information based on one or more feedback signals of the auxiliary signal conversion device.

71. 61. The method of claim 60, wherein the one or more feedback signals comprise voltage levels of one or more capacitors of the auxiliary signal conversion device.

72. 72. The method of claim 70 or 71, wherein the control information comprises one or more modulation indices.

73. 73. The method of claim 72, wherein the one or more modulation indices include a modulation index for each of a plurality of phases.

74. 73. The method of claim 72, wherein the one or more AC loads include a three-phase motor, and the one or more modulation indices include a modulation index for each of its three phases.

75. 75. The method of any one of claims 70 to 74, further comprising generating, by the controller, the processed control information based on (i) one or more operational characteristics of each module of the plurality of modules, (ii) one or more operational characteristics of each array of the plurality of arrays, or (iii) one or more operational characteristics of each subpack of an array.

76. 76. The method of claim 75, wherein the one or more operational characteristics of each module include at least one of a state of charge of the module or a temperature of the module.

77. 77. The method of claim 75 or 76, wherein the one or more operating characteristics of each array include at least one of an aggregated state of charge of the array or an aggregated temperature of the array.

78. 78. The method of any one of claims 75 to 77, wherein the one or more operational characteristics of each sub-pack include at least one of a combined state of charge of the sub-pack or a combined temperature of the sub-pack.

79. 79. A method according to any one of claims 75 to 78, wherein the controller is configured to balance the one or more operating characteristics by adjusting the control information.

80. 62. The method of claim 61 , wherein the auxiliary signal conversion device includes a positive DC line and a negative DC line, and the rectifier circuit includes a capacitor coupled between the positive DC line and the negative DC line.

81. 81. The method of claim 80, wherein the positive DC line is coupled to a positive line of a DC power bus coupled to the one or more DC loads and the negative DC line is coupled to a negative line of the DC power bus, and the auxiliary signal conversion device is configured to adjust a voltage level across the capacitor.

82. The rectifier circuit a plurality of diode segments including a respective diode segment for each array segment of the plurality of array segments, the respective diode segment for each array segment including: (i) a first diode coupled between an output of the array segment and a positive DC line of the rectifier circuit; and (ii) a second diode coupled between the output of the array segment and a negative DC line of the rectifier circuit; a filter circuit coupled to the positive DC rail and the negative DC rail and including a DC coupled output coupled to the one or more DC loads; a local controller configured to obtain one or more feedback signals of the SSCD and provide the feedback signals to an SSCD controller configured to adjust control information for the array of the array segments based on the feedback signals.

83. 83. The method of claim 82, wherein the rectifier circuit further comprises an intermediate DC line.

84. 84. The method of claim 83, wherein a neutral point of each array segment is coupled to the intermediate DC line.

85. 84. The method of claim 83, wherein a phase port of at least one of each of said plurality of arrays is coupled to said intermediate DC line.

86. 86. The method of claim 85, wherein a phase port of each array of subpacks of the array is coupled to the intermediate DC line.

87. 87. The method of any one of claims 83 to 86, wherein the plurality of diode segments includes a diode segment having a first diode coupled between the positive DC line and the intermediate DC line and a second diode coupled between the intermediate DC line and the negative DC line.

88. 88. The method of any one of claims 83 to 87, wherein the first diode of each diode segment is configured to send a positive current to the positive DC rail and the second diode of each segment is configured to send a negative current to the negative DC rail.

89. 89. The method of any one of claims 50 to 88, wherein the one or more AC loads include one or more polyphase loads, and the plurality of arrays includes at least one array for each phase of the one or more polyphase loads.

90. 90. The method of claim 89, wherein each segment includes an array pair for a single phase, each array pair including a first array and a second array.

91. 91. The method of claim 90, wherein a common point of each segment is a common neutral point of the segment, and wherein a neutral point of the first array is coupled to a neutral point of the second array at the common neutral point of the segment.

92. 92. The method of claim 91 , wherein the common neutral point of each segment is coupled to the common neutral point of each other segment.

93. 93. The method of claim 92, wherein the one or more AC loads include two electric vehicle motors.

94. 94. The method of claim 92 or 93, wherein the common neutral point of each segment is coupled to a respective neutral terminal of a connector of a cable connecting the output of each array to a rectifying circuit of the auxiliary signal conversion device.

95. 95. The method of claim 94, wherein the connector includes a respective port for each output of each array.

96. 91. The method of claim 90, wherein the one or more AC loads include a single electric vehicle motor, and wherein the neutral point of the first array is coupled to the neutral point of the second array of each segment without coupling the common neutral point of each segment to the common neutral point of each other segment.

97. selectively coupling, with a first switch, a common neutral point of a first pair of arrays for a first phase to a common neutral point of a second pair of arrays for a second phase; 91. The method of claim 90, further comprising selectively coupling, with a second switch, the common neutral point of the second pair of arrays for the second phase to a common neutral point of a third pair of arrays for a third phase.

98. a module pack including a plurality of segments of an array of modules, each segment of the array including a plurality of coupled arrays, each segment of the array configured to output an AC voltage signal having the same phase angle, the phase angle of the AC signal output by each segment of the array being different from the phase angle of the AC signal output by each other array; a rectifier circuit configured to convert the AC voltage signal output by each segment into a DC signal for one or more auxiliary loads; a control system configured to control the modules of each array to adjust the DC signal to balance one or more operating characteristics of the modules of the array.

99. 100. The system of claim 98, wherein the control system is configured to receive control information from an external device and adjust the control information to condition the DC signal to balance the one or more operating characteristics.

100. 100. The system of claim 98 or 99, wherein the control information includes a modulation index for each segment of the array.

101. 101. The system of any one of claims 98 to 100, wherein the operational characteristics include at least one of a state of charge or a temperature for each module.

102. 102. The system of any one of claims 98 to 101, wherein the operational characteristics include at least one of a state of charge or a temperature for each array.

103. 103. The system of any one of claims 98 to 102, wherein the operating characteristics include at least one of a state of charge or a temperature for each segment.

104. 104. The system of any one of claims 98 to 103, wherein the module pack is configured to supply the AC signals output by each array to one or more electric motors.

105. 105. The system of claim 104, wherein the one or more electric motors comprise an open winding motor.

106. 106. The system of claim 105, wherein the control system is configured to adjust a modulation index for at least one segment to balance the one or more operating characteristics of the modules of the array.

107. A module pack, a first segment of an array comprising: (i) a first array of first modules configured to output a first AC voltage signal having a first phase angle, the first AC voltage signal comprising a superposition of output voltages from the first modules; and (ii) a second array of second modules configured to output a second AC voltage signal having the first phase angle, the second AC voltage signal comprising a superposition of output voltages from the second modules, wherein a first neutral point of the first array is coupled to a second neutral point of the second array; a second segment of the array comprising: (i) a third array of third modules configured to output a third AC voltage signal having a second phase angle, the third AC voltage signal comprising a superposition of output voltages from the third modules; and (ii) a fourth array of fourth modules configured to output a fourth AC voltage signal having the second phase angle, the fourth AC voltage signal comprising a superposition of output voltages from the fourth modules, wherein a third neutral point of the third array is coupled to a fourth neutral point of the fourth array; a third segment of the array comprising: (i) a fifth array of fifth modules configured to output a fifth AC voltage signal having a third phase angle, the fifth AC voltage signal comprising a superposition of output voltages from the fifth modules; and (ii) a sixth array of sixth modules configured to output a sixth AC voltage signal having the third phase angle, the sixth AC voltage signal comprising a superposition of output voltages from the sixth modules, wherein a fifth neutral point of the fifth array is coupled to a sixth neutral point of the sixth array; a first set of ports for coupling each phase output of at least one array in each segment to one or more three-phase loads; a second set of ports for coupling at least one array of each segment to a rectifier circuit, the rectifier circuit configured to convert the AC voltage signal to a DC signal for powering one or more auxiliary loads.

108. A rectifier circuit, a positive DC line; an intermediate DC line; a negative DC line; a diode circuit including a set of diode segments each including two diodes coupled between a positive DC line and a negative DC line; a filter circuit including an inductor disposed along the positive DC line, a first capacitor coupled between the positive DC line and the intermediate DC line, and a second capacitor coupled between the intermediate DC line and the negative DC line.

109. 109. The rectifier circuit of claim 108, wherein a phase output of the array of modules is coupled between the two diodes of at least a subset of the diode segments.

110. 110. A rectifier circuit as claimed in claim 108 or 109 implemented in a system as claimed in any one of claims 1 to 49 or 98 to 106.

111. A cable, a first connector at a first end of the cable, the first connector including a plurality of first ports configured to mate with a module pack including a first plurality of arrays of modules and a second plurality of arrays of modules, the plurality of first ports including a respective port for each array and one or more first neutral ports for one or more corresponding neutral points of the arrays; a second connector at a second end of the cable, the second connector including a plurality of second ports corresponding to the plurality of first ports; The second connector is configured to connect to the rectifier circuit in a first orientation for an electric vehicle having a single motor and to connect to the rectifier circuit in a second orientation different from the first orientation for an electric vehicle having two motors.

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