Power string module and method for using and manufacturing the same

Abstract

To combine battery energy and voltage and hardware for DC / DC conversion into a single product rather than separate products, and furthermore, to enable the deployment of such a single product in existing vehicles, especially large off-highway vehicles, and / or other large power systems. [Solution] In one implementation configuration, the device includes a housing and an energy module which includes (1) a battery pack contained within the housing and configured to provide an initial voltage. The device further includes a conversion module which includes (1) a high-voltage DC / DC converter and an ultra-high-voltage DC / DC converter. The conversion module is configured to receive an initial voltage and output a converted voltage using the high-voltage DC / DC converter and the ultra-high-voltage DC / DC converter.

Description

Technical Field

[0001] Cross - reference to Related Applications This application claims the benefit and priority of U.S. Provisional Application No. 63 / 719,957, filed on November 13, 2024, the disclosure of which is hereby incorporated by reference in its entirety into this specification.

[0002] The implementations described herein relate to power systems, and more specifically, to power string modules that enclose batteries and converters.

Background Art

[0003] Despite contributing to harmful anthropogenic greenhouse gas emissions, the energy sources for most vehicles, stationary power systems, etc. continue to be the burning of fossil fuels in internal combustion engines. There is recent pressure to move from vehicles and / or stationary power systems powered by fossil fuels (e.g., diesel) to hybrid and / or fully electric vehicles and / or stationary power systems in order to reduce greenhouse gas emissions.

[0004] Several difficulties continue to hinder the widespread adoption of alternative power sources. For example, larger, heavier batteries are often used for electric vehicles to achieve the same range as fossil fuel-powered vehicles. Furthermore, as electric vehicles become larger and heavier and are applied in off-road conditions, the difficulties of powering the vehicles increase. For example, as vehicles get larger (or as power demands increase in some implementations such as stationary power systems), the batteries used to power the vehicle / system may become heavier, larger, consume more energy, get hotter, pose a safety hazard, take longer to charge, and be subject to stricter regulations and standards. Also, the high voltages used in such power systems can increase safety risks, thermal management complexities (e.g., if heat generation increases), unwanted electromagnetic interference, and weight and stress on components. These difficulties become more pronounced, for example, when these power systems (e.g., power systems contained in mining vehicles / equipment, locomotives, ships, etc.) are used in off-highway settings or other potentially harsh environments. Off-road settings or environmental influences can increase risks such as battery water damage, mechanical damage due to uneven terrain, and fire due to overheating or short circuits, often requiring robust and / or reinforced designs.

[0005] These difficulties are further amplified in situations where existing vehicles or power systems are being modified. For example, designing a "clean sheet" for mining hole trucks powered by alternative power sources (e.g., hybrid diesel / battery power plants, hybrid hydrogen / battery power plants, all-electric power plants, etc.) would involve substantial expense and long lead times before such trucks could be deployed in large numbers to mining sites, lagging behind the environmental and cost benefits of powering such vehicles with alternative power sources rather than fossil fuels like diesel. Similarly, modifying existing stationary power systems to electric would involve substantial expense and lead times. Rather than redesigning electric off-highway vehicles or stationary power systems from scratch and assuming responsibility for some of the difficulties upfront, it would be possible to modify or at least partially modify vehicles or stationary power systems to include such alternative power sources. However, modifying existing vehicles or stationary power systems introduces unique difficulties, such as compatibility issues, spatial constraints, and centralized control systems.

[0006] Some hybrid and / or electric vehicles use battery packs. However, some battery packs may not be optimized for such use because they were not designed for industrial and / or large-scale implementations. For example, some battery packs may use enclosures that do not include devices for voltage and / or current regulation and conversion, as integrating such devices may not be necessary or desirable in smaller-scale applications. Instead, the battery power / storage and regulation / conversion devices may exist as separate components housed in separate enclosures. However, handling voltage conversion using separate enclosures can add complexity to the wiring harness (for example, properly sealing and protecting multiple enclosures can be more complex than properly sealing and protecting a single, integrated enclosure), add complexity to cooling (for example, multiple separate enclosures may use separate cooling systems, which can complicate thermal management), and add complexity to integration (for example, separate enclosures may use additional wiring and connections between them to ensure all enclosures work together, which increases the risk of failure and introduces potential vulnerabilities). [Overview of the project] [Problems that the invention aims to solve]

[0007] Therefore, it may be desirable to combine battery energy and voltage with hardware for DC / DC conversion into a single product rather than separate products. Furthermore, it may be desirable that such a single product be adaptable to existing vehicles, particularly large off-highway vehicles, and / or other large power systems (e.g., stationary power systems). [Means for solving the problem]

[0008] In one implementation configuration, the device includes a housing and an energy module contained within the housing. The energy module includes a battery pack configured to provide an initial voltage. The device further includes a conversion module contained within the housing. The conversion module includes a high-voltage DC / DC converter and an ultra-high-voltage DC / DC converter. The conversion module is configured to receive an initial voltage and output a converted voltage using the high-voltage DC / DC converter and the ultra-high-voltage DC / DC converter. [Brief explanation of the drawing]

[0009] [Figure 1] This is a system block diagram of at least a part of a power system in one implementation configuration. [Figure 2] This is a flowchart illustrating a method for generating a converted voltage using a single implementation configuration. [Figure 3] This is a circuit diagram of a power string module in one implementation configuration. [Figure 4] This figure shows a power supply / sink in a power system, electrically coupled to a high-voltage routing channel in one implementation configuration. [Figure 5] This diagram shows the conversion module and energy module in separate enclosures. [Figure 6A] This diagram shows a power string module for a power system in one implementation configuration. [Figure 6B] This figure shows the inboard side of the power string module, as seen in Figure 6A. [Figure 6C] This figure shows the outboard side of the power string module, as seen in Figure 6A. [Figure 6D] This figure shows the various components of the power string module arranged in the enclosure, as shown in Figure 6A. [Figure 6E] This is a bottom view of some of the components of the power string module, as shown in Figure 6A, arranged in the enclosure. [Figure 6F] This is a top view of some of the components of the power string module, as shown in Figure 6A, arranged in the enclosure. [Figure 7A] This is a side view of part of a car, including the power system. [Figure 7B] Figure 7A is an inboard perspective view of a portion of the power system, showing one set of energy modules and a separate set of conversion modules. [Figure 7C] Figure 7A is an outboard perspective view of a portion of the power system, showing one set of energy modules and a separate set of conversion modules. [Figure 7D] Figure 7A is an enlarged side view of the power system. [Figure 8A] This is an outboard perspective view of at least a portion of a car's power system, including a set of power string modules in one implementation configuration. [Figure 8B] Figure 8A is an outboard perspective view of at least a portion of the power system, with some components removed to better show the power string modules housed within the enclosure. [Figure 8C] Figure 8A is an inboard perspective view of a portion of the power system, showing the electrical connections related to multiple power string modules. [Figure 8D] Figure 8A is an outboard perspective view of a portion of the power system, showing the electrical connections related to multiple power string modules. [Figure 9] This is a perspective view of at least a part of a power system in one implementation configuration. [Modes for carrying out the invention]

[0010] Some implementations relate to a power string module. The power string module can be configured to provide power to, for example, an electric vehicle (or a hybrid electric vehicle). In some implementations, the vehicle can be, for example, a mining haul truck, a locomotive, a ship, and / or other large industrial vehicles (e.g., ultra-class vehicles). Additionally, or alternatively, in some implementations, the power string module can be introduced into an existing vehicle. For example, a vehicle powered by fossil fuel, such as a vehicle with a diesel combustion engine, can be modified to include a power string module (e.g., a modification to a diesel / battery hybrid power plant). Alternatively, a conventional combustion engine can be removed from an existing vehicle, and the vehicle can be modified to include a power string module (e.g., a modification to an all-electric power plant). Additionally, or alternatively, in some implementations, the power string module can be configured to provide power to a vehicle configured to move off-road in a mining environment. As another example, a fossil fuel-based stationary power system can be modified to include the power string module described herein and / or otherwise supplemented or replaced with it.

[0011] In some implementations, the power string module includes a housing of one or more energy modules (e.g., battery packs) and one or more conversion modules (e.g., a voltage converter such as a DC / DC converter). In some implementations, the power string module is used to supply and / or absorb high voltage DC power regulated for, for example, hybrid electric vehicles (HEVs) and / or all-electric vehicles. In some implementations, the battery pack and the DC / DC conversion are integrated into one product, thereby addressing many of the drawbacks of having the previously mentioned energy module and conversion module in separate housings.

[0012] In some implementations, the power string module has multiple battery packs. In some implementations, the power string module includes at least 14 battery packs. In some implementations, the battery packs within the power string module can be removed (for example, if not needed for a particular use case) and / or not installed, providing greater adaptability compared to systems where full integration of all power components is required (for example, for deployment in existing vehicles).

[0013] Figure 1 shows a system block diagram of at least a portion of the power system 100 (also referred to herein as "system 100") in one implementation configuration. System 100 may include one or more power string modules, such as power string module 102A and power string module 102B. Each power string module may include an energy module and a conversion module within its own separate enclosure. In some implementation configurations, system 100 is included in a diesel / battery hybrid vehicle. A diesel / battery hybrid vehicle may be, for example, a mining hole truck, a locomotive, a ship, or any other suitable diesel / battery hybrid vehicle. Alternatively, system 100 can be implemented in a stationary power system (e.g., a power plant). Thus, a vehicle, a power plant, etc., may include electrical components configured to be powered by one or more power string modules (e.g., power string module 102A, power string module 102B, etc.).

[0014] As shown in FIG. 1, the power string module 102A includes a housing 101A that houses and / or encapsulates an energy module 104A and a conversion module 106A (operatively coupled to each other). Similarly, the power string module 102B includes a housing 101B that houses and / or encapsulates an energy module 104B and a conversion module 106B (operatively coupled to each other). Each conversion module can include one or more DC / DC converters (e.g., multiple DC / DC converters, only two DC / DC converters, only one DC / DC converter, etc.). For example, the conversion module 106A includes a high-voltage (e.g., from 60 volts direct current (VDC) to 1,500 VDC) DC / DC converter 108A and an ultra-high voltage (e.g., greater than 1,500 VDC) DC / DC converter 110A, and the conversion module 106B includes a high-voltage DC / DC converter 1OB and an ultra-high voltage DC / DC converter 110B. In some implementations, at least one DC / DC converter can include at least one buck converter and at least one boost converter. The techniques described herein accommodate larger vehicles using high-voltage and ultra-high voltage DC / DC converters, but in some implementations (e.g., for smaller vehicles), other, low-voltage DC / DC converters can be used.

[0015] The energy module 104A may include one or more battery packs, each of which may include a battery cell. In some implementations, multiple battery cells are used for the energy module 104A, and the multiple battery cells are in series (e.g., not in parallel). One or more battery packs are configured to provide an initial voltage. The conversion module 106A is configured to receive the initial voltage and output a converted voltage using a high-voltage DC / DC converter 108A and an ultra-high-voltage DC / DC converter 110A. For example, the high-voltage DC / DC converter 108A may be configured to receive the initial voltage from the energy module 104A and generate an intermediate voltage. Then, the ultra-high-voltage DC / DC converter 110A may be configured to receive the intermediate voltage from the high-voltage DC / DC converter 108A and generate a converted voltage.

[0016] Similarly, the energy module 104B may include one or more battery packs, each of which may include a battery cell. One or more battery packs are configured to provide an initial voltage. The conversion module 106B is configured to receive the initial voltage and output a converted voltage using a high-voltage DC / DC converter 108B and an ultra-high-voltage DC / DC converter 110B. For example, the high-voltage DC / DC converter 108B may be configured to receive the initial voltage from the energy module 104B and generate an intermediate voltage. Then, the ultra-high-voltage DC / DC converter 110B may be configured to receive the intermediate voltage from the high-voltage DC / DC converter 108B and generate a converted voltage.

[0017] In some implementations, energy modules 104A and / or 104B can be configured to provide an initial voltage, and ultra-high voltage DC / DC converters 110A and / or 110B can be configured to receive the initial voltage and generate an intermediate voltage. Then, high voltage DC / DC converters 108A and / or 108B can be configured to receive the intermediate voltage from ultra-high voltage DC / DC converters 110A and / or 110B and generate a conversion voltage. Thus, DC / DC converters 108A and / or 108B can be configured to "boost" and / or "buck" the initial voltage.

[0018] In some implementations, each power string module includes and / or is housed in a separate enclosure. In other words, power string modules 102A and 102B are each housed in their own separate enclosures 101A and 101B, which each include and / or house their own separate energy modules 104A and 104B, and conversion modules 106A and 106B, respectively. Thus, in some implementations, power string module 102A can generate an initial voltage and output a converted voltage independently of other circuitry outside of power string module 102A. Similarly, power string module 102B can generate an initial voltage and output a converted voltage independently of other circuitry outside of power string module 102B. Rather than separating energy components (e.g., energy module 104A) from conversion components (e.g., conversion module 106A) using different enclosures, combining the components of each power string module within a single enclosure (e.g., enclosure 101A or 101B) offers advantages such as reduced complexity, improved cooling, and improved wiring. For example, when the components of each power string module are in a single enclosure, the advantages may include: the components and power string modules having spacing that satisfies creepage and spatial distance requirements; reduced wiring as a result of the proximity of components within the enclosure; reduced external wiring as a result of internal wiring; the enclosure protecting the orientation of components (e.g., vertical / horizontal to account for impacts, etc.); reduced assembly time of system 100 because the enclosure can be easily removed and replaced, thereby allowing the power string modules to be removed and replaced; and other desirable parameters relating to system 100. While the techniques described herein may be suggested in a variety of use cases, the advantages may be particularly desirable for off-highway hybrid / electric or all-electric vehicles given these demanding power and environmental requirements.For example, if the energy components and conversion components are housed in separate enclosures, and the hybrid electric vehicle encounters a severe jolt, there is a greater likelihood that one or both components may be, for example, cut, improperly sealed, or improperly oriented. Also, housing the energy components and conversion components in the same enclosure allows for increased flexibility, modularity, and / or adaptability. That is, by housing the energy components and conversion components in the same enclosure, it becomes possible to quickly replace and connect the energy components and conversion components and disconnect them from system 100, and the space occupied by the energy components and conversion components within system 100 is less than when they are housed separately, thus improving adaptability.

[0019] In some implementations, system 100 includes an outer enclosure and / or support structure that houses the power string modules included in system 100. For example, the outer enclosure and / or support structure can provide a structure or feature for mounting the power string modules in a vehicle. That is, all power string modules in system 100 can be placed in an outer enclosure and / or support structure that can protect the power string modules from external influences (e.g., debris, wind, water, etc.). However, in some implementations, such an enclosure or support structure can partially cover the power string modules while leaving other sides of the power string modules exposed. For example, such an enclosure and / or support structure can leave the top (or any other suitable part) of each power string module exposed to allow physical and / or electrical access, thermal management, etc.

[0020] In some implementations, not shown in Figure 1, system 100 may include and / or be used with a cooling system. The cooling system may be configured to lower the temperature of components contained in power string modules 102A and 102B. Since the techniques described herein can be applied in high-voltage and / or ultra-high-voltage situations that may lead to increased heat generation, the cooling system can be used to regulate the temperature of power string modules 102A and 102B (and / or one or more of their components) to a predetermined acceptable range. In some implementations, a single cooling system is used to cool all power string modules contained in system 100. Alternatively, system 100 may include multiple cooling systems (or subsystems), with each power string module being cooled by a separate, individual, or dedicated cooling system (or subsystem). Alternatively, system 100 may include separate, individual, or dedicated cooling systems (or subsystems) for cooling the energy module and conversion module of each power string module.

[0021] Figure 2 shows a flowchart of method 200 for generating a conversion voltage in one implementation configuration. In 202, an initial voltage is provided via a first module (e.g., energy module 104A) contained within a power string module enclosure (e.g., enclosure 101A). In some implementation configurations, the power string module is contained within a diesel / battery hybrid vehicle (e.g., mining hole truck, locomotive, ship, etc.). In 204, the initial voltage is received by a first DC / DC converter (e.g., high-voltage DC / DC converter 108A) contained within the enclosure, and an intermediate voltage is generated. In 206, the intermediate voltage is received by a second DC / DC converter (e.g., ultra-high-voltage DC / DC converter 110A) contained within the enclosure, and a conversion voltage is generated. The conversion voltage may be, for example, higher, equal to, or lower than the initial voltage.

[0022] Figure 3 shows a circuit diagram of a power string module in one implementation configuration (for example, power string modules 102A and / or 102B described above with reference to Figure 1). This circuit diagram shows the voltage source 302 and power converters 304 and 306, among other electrical components. In addition, the circuit may include electrical components such as one or more disconnects (e.g., DISC1 and DISC2), one or more switches (e.g., K1, K2, and K3), one or more resistors (e.g., R1), one or more diodes (e.g., D1) protecting at least the second DC / DC converter, one or more fuses (e.g., F1, other fuses) configured to protect electrical components from overcurrent conditions, one or more insulation monitors (e.g., IMD1) configured to monitor the resistance between two or more conductors in the circuit, one or more voltage transducers (e.g., VT1) configured to sense voltage along at least part of the circuit, and one or more current transducers (e.g., CT1) configured to sense current along at least part of the circuit. IMD1, C1, and C2 can be connected to or grounded by the vehicle's chassis.

[0023] The voltage source 302 may be, for example, a battery-based (e.g., lithium-ion based) onboard power storage system including any number of battery packs. The voltage source 302 in Figure 3 may be, for example, defined as 504-910 volts (VDC) at 30.9 kWh, and / or can provide this, but other types of battery packs and / or other voltage and power ratings may be used in some implementations. The voltage generated by the voltage source 302 is received by a power converter 304 (e.g., a first power converter), which produces at least one output having an intermediate voltage. The intermediate voltage is then received by a power converter 306 (e.g., a second power converter), which outputs a converted voltage.

[0024] As shown in Figure 3, the first power converter 304 may be a first DC / DC converter configured to receive a voltage from a voltage source (e.g., a battery pack), convert this voltage to an intermediate voltage, and provide one or more outputs of the intermediate voltage. The first power converter 304 may be configured such that the currents associated with each voltage output are the same (or substantially the same) or different. For example, the first power converter 304 may have two outputs, one received by a second power converter 306 and the other received by one or more auxiliary systems. The first intermediate voltage output from the first power converter 304 may have a higher current (e.g., 950VDC at 360 amps) than the second intermediate voltage output (e.g., 950VDC at 120 amps). The second power converter 306 (e.g., a second DC / DC converter) may receive the first intermediate voltage output from the first power converter 304 and convert the intermediate voltage to a conversion voltage. The converted voltage may be an ultra-high voltage suitable for delivery to, for example, the drive system or similar drive / power system of an ultra-class vehicle (e.g., 2,400 VDC at 200 amps). In addition, the auxiliary system may receive a second intermediate voltage output from the first power converter 304. For example, the auxiliary system may be configured to power vehicle components that are not part of the drive system, such as lights, radio, air conditioning, windows, pumps, and cooling systems, while the drive system may be configured to propel the vehicle (for example, by converting the converted voltage into mechanical power that drives the wheels via one or more drive motors).

[0025] Figure 4 shows a power supply / sink 400 in a single implementation configuration, electrically coupled to a high-voltage routing channel and part of a power system. The power supply / sink 400 may include an energy module 402 and a conversion module 404. Although not shown in Figure 4, each pair of energy modules 402 and conversion modules 404 can be combined and / or housed in a single enclosure (for example, rather than in separate enclosures). By combining them in a single enclosure, advantages such as improved volumetric efficiency, reduced mechanical complexity, simplified interconnect and safety systems, and reduced external high-voltage routing can be achieved. For example, the energy modules 402 and conversion modules 404 can be arranged with spacing for creepage and clearance requirements, and this spacing can also contribute to cooling and a reduction in overall wiring, and especially external wiring, while the enclosure protects the orientation of the components of the energy modules 402 and conversion modules 404, and the enclosure can be quickly removed and replaced, thereby reducing the assembly time of the power supply / sink 400. Energy module 402 and conversion module 404 may be included in a first power string module, which further includes a housing that accommodates and / or encloses the energy module 402 and conversion module 404. As shown in Figure 4, the power supply / sink 400 may also include additional energy modules and conversion modules. The additional energy modules and conversion modules may have a similar or substantially the same configuration as energy module 402 and conversion module 404, and each may be housed in a housing to form any number of power string modules. For this reason, additional power string modules are not described in detail herein.

[0026] The energy module 402 may include one or more battery packs 406 and may be electrically coupled to a battery management system (BMS) 408. In some implementations, the energy module 402 may include, for example, 14 battery packs 406 connected in series. In other implementations, the energy module 402 may include more or fewer battery packs 406. The output from the energy module 402 may be received by a conversion module 404. The conversion module 404 includes a switch 410, which, when closed, allows the output from the energy module 402 to be received by a high-voltage DC / DC converter 412. The output from the high-voltage DC / DC converter 412 may then be received by an ultra-high-voltage DC / DC converter 416. A battery power string controller (BPSC) 418 may also be electrically coupled to the BMS 408 (for example, by turning the BMS 408 on or off, and / or by opening one or more circuits to disconnect the battery packs 406).

[0027] The BMS regulator 414 can be configured to regulate the BMS 408. For example, the BMS regulator 414 can be configured to repeatedly (e.g., continuously, periodically, or sporadically) monitor voltage, current, temperature, charge status, etc., in the energy module 402 and / or the conversion module 404. In response to a predetermined trigger (e.g., overcharge, overdischarge, overheat, short circuit), the BMS regulator 414 can perform one or more actions and / or be prompted to perform one or more actions to address the triggered condition (e.g., send an electrical signal to the BMS 408 to open a switch, activate a cooling system). In some implementations, the BMS regulator 414 is configured to be a controller.

[0028] As used herein, “controller” (e.g., BPSC418, BMS regulator414) may include (or be) any suitable controller or control system. For example, the controller may be and / or part of a hybrid vehicle controller. That is, a vehicle control system may be used as a controller to control the operation of a power string module, and / or may be modified to function as a controller. The controller may include any suitable components that enable the operation of the control system. In some implementations, the controller may include at least a processor configured to execute instructions or code stored in memory. Such a processor may be, for example, a hardware-based integrated circuit (IC), or any other suitable processing unit configured to run and / or execute a set of instructions or code. For example, the processor may be a general-purpose processor, a central processing unit (CPU), an accelerated processing unit (APU), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a programmable logic array (PLA), a complex-programmable logic device (CPLD), a programmable logic controller (PLC), and so on. In some implementations, the processor can be configured to perform one or / or some of the methods discussed herein.

[0029] The controller may include any suitable memory or storage medium. For example, memory may be or may include random access memory (RAM), memory buffers, hard drives, read-only memory (ROM), erasable programmable read-only memory (EPROM), etc. In some cases, memory may store one or more software programs and / or code that include instructions causing the processor to execute one or more processes, functions, etc. In some implementations, memory may include expandable storage units that can be added and used incrementally. In some implementations, memory may be portable memory (e.g., flash drives, portable hard disks, etc.) that can be operationally coupled to the processor. In some cases, memory may be remotely operationally coupled to a computing device (not shown). For example, a remote database device may function as memory and be operationally coupled to a computing device. Memory may include various components (e.g., machine-readable media) including, for example, random access memory (RAM) components, read-only components, and any combination thereof. In one example, a basic input / output system (BIOS), which includes basic routines that help transfer information between elements within a computing system (e.g., a controller) during startup, can be stored in memory. The memory may further include any number of program modules, including, for example, an operating system, one or more application programs, other program modules, program data, and any combination thereof.

[0030] Figure 5 shows the energy module 502 and the conversion module 504 in separate enclosures. As shown in Figure 5, the energy module 502 and the conversion module 504 are each housed in separate enclosures (rather than being combined in one enclosure). Therefore, in order to produce the desired voltage, the energy module 502 and the conversion module 504 must be properly coupled (e.g., electrically and / or mechanically). However, in separate enclosures, there are numerous vulnerabilities, such as improper sealing of the energy module 502, improper sealing of the conversion module 504, mechanical disconnection of the conversion module 504 and the energy module 502, electrical disconnection of the conversion module 504 and the energy module 502, or someone improperly coupling the wrong conversion module to the wrong energy module. In addition, in implementations where an existing vehicle (e.g., a mining hole truck) is modified to include a power system, the space for the power system may be limited. In such an implementation configuration, having the energy module 502 and the conversion module 504 in separate enclosures can result in an inefficient use of space, which in turn may limit the number of battery packs that can be included in each energy module 502.

[0031] In contrast, Figure 6A shows a power string module 606 in one implementation configuration. In some implementation configurations, the power string module 606 includes the energy module and the conversion module in a single enclosure 601. In such configurations, the drawbacks discussed with respect to Figure 5 are mitigated (and in some cases even eliminated).

[0032] Figure 6B shows the inboard side of the power string module 606. At least the inboard side of the power string module 606 and / or the housing 601 may include, for example, a low-voltage bundle 602, a coolant inlet port 604, a coolant outlet port 608, and a vent 610. The low-voltage bundle 602 is an interface, connection, input / output, etc., and / or may include, that enables the power string module 606 to be electrically coupled to one or more auxiliary or relatively low-voltage components, devices, systems, etc., that do not require high voltage levels related to powering the vehicle's drive system. The coolant inlet port 604 may be configured to receive coolant (for example, from a heat exchanger, chiller, etc.) and transport it through the housing 601 to cool the components of the power string module 606 or otherwise remove heat from them. The coolant outlet port 608 can be configured to output and / or transport a coolant flow from the housing 601 or the power string module 606 (for example, the outlet flow of coolant after the coolant has absorbed heat from the components of the power string module 606). The vent 610 can be configured to allow airflow into and / or from the housing 601. In some implementations, the airflow passing through the housing 601 can further dissipate the heat released by the components of the power string module 606, preventing overheating and ensuring that the components remain cool for efficient operation. Using the coolant inlet port 604, the coolant outlet port 608, and the vent 610, the power string module 606 can be maintained within a predetermined, acceptable, and / or desired temperature range, which may be particularly desirable in high-power systems.

[0033] Figure 6C shows the outboard side of the power string module 606. At least the outboard side of the power string module 606 and / or the enclosure 601 may include electrical interfaces such as a positive high-voltage connector, port, terminal, etc. (HV+ terminal 611), a negative high-voltage connector, port, terminal, etc. (HV- terminal 612), a positive high-voltage auxiliary connector, port, terminal, etc. (HVAux+ terminal 614), and a negative high-voltage auxiliary connector, port, terminal, etc. (HVAux- terminal 616). At least the outboard side of the power string module 606 and / or the enclosure 601 may further include, for example, one or more grounding studs 622, a negative manual service disconnect (MSD-618), and a positive manual service disconnect (MSD+620). The power string module 606 can be connected to a drive system configured to propel the vehicle (for example, by converting a converted voltage into mechanical power to drive the wheels via one or more drive motors) using the HV+ terminal 611 and the HV- terminal 612. The power string module 606 can be connected to an auxiliary system configured to power vehicle components that are not part of the drive system using the HVAux+ terminal 614 and the HVAux- terminal 616. The grounding stud 622 is configured to provide one or more grounding connections to the power string module 606. The MSD-618 and MSD+620 can be configured to isolate a circuit or system from its power source (i.e., the battery pack included in the power string module 606).

[0034] Figure 6D shows various components of a power string module 606 housed in a housing 601 (for example, the housing 601 is shown as partially transparent). The power string module 606 includes a battery pack 626, a power string management component 623 (and / or device), and a conversion component 624 (and / or device). In this configuration, the power string module 606 includes 14 battery packs. Figure 6E illustrates a bottom view of the power string module 606, showing the 14 battery packs and the wires or other interconnects that electrically connect the battery packs in series. Although the power string module 606 is shown in Figures 6D and 6E as including 14 battery packs 626, in some configurations, the power string module 606 may include fewer or more battery packs than 14.

[0035] The power string module 606 is configured to supply power (or voltage) to the battery pack 626 and to the electrical circuit shown in detail in Figure 6F, which includes the power string management component 623 and the conversion component 624. For example, the power string management component 623 (shown within the dashed line in Figure 6F) could include a battery management system (BMS650) that is structurally and / or functionally similar to the BMS408 described above with reference to Figure 4, for example. The power string management component 623 may further include one or more isolation monitoring devices (ICM638) configured to monitor the resistance between two or more conductors in the circuit; one or more current sensors 640 configured to sense current along at least a portion of the circuit; one or more fuses 642 configured to protect at least a portion of the electrical components from overcurrent conditions; one or more voltage transducers 652 configured to sense voltage along at least a portion of the circuit; one or more resistors 654 configured to resist a portion of the current flow along at least a portion of the circuit; and one or more contactors 656 configured to provide switching along, for example, the high-current / high-voltage portion of the circuit. In one example, the power string management component 623 can activate / isolate a power string module 606 in response to a predetermined set of criteria (e.g., temperature, current, or voltage outside a predetermined acceptable range) in the battery pack 626 and / or conversion component 624, in the MSD-618 and / or MSD+620 (shown in Figures 6C and 6F).

[0036] The conversion component 624 can include any suitable conversion hardware. For example, as shown in Figure 6F, the conversion component 624 includes an ultra-high voltage DC / DC converter (DCUHV628), a high voltage DC / DC converter (DCHV648), one or more diodes 646, a low voltage distribution block 630, a regulator 632, an Ethernet converter 634, and an electronic control unit (ECU636). The DCUHV628 and DCHV648 are electrically connected in series with one or more diodes 646 between them. The conversion component 624 can be configured to receive power from the battery pack 626, convert and / or modify the received energy, and output the converted voltage to, for example, a high voltage busbar 644 (for example, this then includes, or is electrically connected to, HV+ terminal 611, HV- terminal 612, HVAux+ terminal 614, and HVAux+ terminal 616 (collectively referred to as the “HV terminals”)). Alternatively, during regeneration, the conversion component 624 may receive an input voltage from, for example, a blocking grid or other suitable device (e.g., via the HV terminal and HV busbar 644), convert and / or modify the received energy, and output a converted voltage used to recharge the battery pack 626.

[0037] Figure 7A shows a power system installed in a hybrid / electric or all-electric vehicle (e.g., a diesel / battery hybrid or all-electric mining truck). Figure 7A includes an energy module 702 and a conversion module 704. As shown, each of the energy module 702 and the conversion module 704 has its own separate module / enclosure. In other words, the energy module 702 and the conversion module 704 are separated within different enclosures.

[0038] Figure 7A also shows that the energy module 702 is enclosed in the housing / support structure 714, and that the conversion module 704, positioned above the energy module 702, extends above the housing / support structure 714 in Figure 7A. As shown in Figure 7A, the distance between the top of the energy module 702 and the conversion module 704 may be approximately 100 millimeters (mm). Figure 7A also shows a cooling system 706. The cooling system 706 can be configured to cool the energy module 702 and / or the conversion module 704. A single cooling system can be used, as shown in Figure 7A.

[0039] Figure 7B shows a perspective view of the inboard side of the car, including multiple conversion modules 704 and an energy module. It connects to the voltage output using a high-voltage (HV) interconnect 708. Low-voltage (LV) components 710 represent low-voltage components (e.g., lights, radio, air conditioning, windows) that are not involved in supplying power to the car's drive system. The MT coolant loop 712 is used to cool the heat generated by the manual transmission using engine coolant circulating through a dedicated transmission cooler. Figure 7B shows the conversion module 704.

[0040] Figure 7C shows the outboard side of the vehicle from Figure 7B. The HV I / O 718 can be configured to transmit and / or receive data. The isolation switch 715 can be configured to function as an isolation switch (for example, to disconnect or reconnect the power string module from other electrical components). Similarly, the isolation switch 715 can be configured to selectively isolate the power system (i.e., the battery power system) from the truck's electrical system. The LT coolant loop 716 can be configured to manage the temperature of the vehicle's transmission fluid. The energy module 702 is located below the converter module 704. Figure 7D shows an enlarged side view of part of the power system. Figure 7D shows the blocking grid 720 and support structure located above the energy module 702, the converter module 704, and the housing / support structure 714. As shown in Figure 7D, the blocking grid 720 is located close to the energy module 702 and the converter module 704, which may be undesirable in some situations. For example, placing the blocking grid 720 near the energy module 702 and the conversion module 704 could lead to problems such as thermal management (e.g., component degradation due to excessive heat), electrical interference (e.g., EMI issues), and shock (e.g., the blocking grid 720 hitting the conversion module 704 or the energy module 702 (or vice versa)).

[0041] Furthermore, when implemented in a mining hole track, the track's tray may extend above the deck, which in turn restricts the height of components fixed to the deck. In some implementations, it may be undesirable to raise the blocking grid 720 to provide additional space between the blocking grid 720 (or its support structure) and the conversion module 704. Thus, the limited amount of space may impose restrictions on the size, number, and / or configuration of the battery packs included in the energy module 702.

[0042] Figure 8A shows an outboard perspective view of at least a portion of a car's power system, including a set of power string modules, in one implementation configuration. Figure 8A shows the power string module 802, housing / support structure 804, cooling system 810, electrical cabinet 806, blocking grid 808, and converter 812. The cooling system 810 can be configured to maintain and / or correct the temperature of the power string module 802. The blocking grid 808 can be used to slow down the car or maintain a constant speed of the car, and can be used to generate power to recharge the battery pack contained in the power string module 802. The converter 812 is configured as a high-level converter / isolator that enables the integration of the power string module 802 into the car's existing electrical system (and / or together with the blocking / recharge / regeneration system). Not shown, the power system can be electrically connected to one or more components in the electrical cabinet 806 (e.g., via any number / type of interfaces).

[0043] Figure 8B illustrates an outboard perspective view of at least a portion of the power system in Figure 8A, with some components removed to better show the power string module. Figure 8B shows the power string module 802, housing / support structure 804, electrical cabinet 806, and cooling system 810, but does not show the blocking grid 808 and converter 812 from Figure 8A. Together, the power string module 802, housing / support structure 804, cooling system 810, blocking grid 808, and / or converter 812 work together to operate the vehicle in a way that is less prone to failure and unwanted risks, despite the difficulties of modifying and powering a large electric vehicle.

[0044] Figures 8C and 8D show inboard and outboard perspective views, respectively, of the portion of the power system in Figure 8A that illustrates the electrical connections associated with multiple power string modules. The blocking grid 808 is located above the power string module 802. The MT coolant 816 and low-voltage components 814 are located adjacent to the power string module 802. In addition to the converter 812, power string module 802, and blocking grid 808, Figure 8D shows the large isolation switch 818, HV I / O 820, and LT coolant 822.

[0045] Figure 9 shows a perspective view of at least a portion of the power system 900 in one implementation configuration. The power system 900 can be modular or substantially modular, and can be used in any number of implementation configurations. For example, in some implementation configurations, the power system 900 can be used and / or installed on the right deck of a mining hole track. In some implementation configurations, the power system 900 can be used and / or installed on other large / industrial vehicles such as locomotives, ships, and airplanes. Furthermore, in some implementation configurations, the power system 900 can be used and / or installed in a stationary power plant.

[0046] Figure 9 shows a power system 900 including multiple power string modules 902, a block grid 904, a DC link disconnect 906, a thermal management system tower disconnect (TMS disconnect 908), a computing module 910, an under-deck routing channel 912, and an isolation switch 914. The block grid 904 can be located above the power string modules 902 (for example, but without direct connection). The block grid 904 can be any other regenerative energy system configured to output electrical energy used to recharge a regenerative braking system and / or a battery pack contained in the power string modules 902. The isolation switch 914 can be configured to connect or disconnect the power string modules 902 to or from other electrical components of the vehicle. The computing module 910 can communicate with the TMS disconnect 908 and the DC link disconnect 906 and, for example, control one or more of their associated components at least partially. For example, the TMS disconnect 908 can be configured to monitor the temperature of the power string module 902, and the DC link disconnect 906 can be configured to monitor the DC voltage at or associated with the output of the power string module 902. In some implementations, the calculation module 910 can receive an index of the temperature at the power string module 902 from the TMS disconnect 908 and / or an index of the DC voltage level at or associated with the output of the power string module 902 from the DC link disconnect 906. When the temperature and DC voltage levels are within a predetermined, desired, and / or acceptable range, the calculation module 910 can control the isolation switch 914, or otherwise close it, thereby allowing the power string module 902 to be connected to one or more external circuits (e.g., a car).Conversely, in response to either or both the temperature and / or DC voltage level being outside a predetermined, desired, and / or acceptable temperature or DC voltage level range, respectively, the calculation module 910 signals the isolation switch 914 to open it, thereby disconnecting the power string module 902 from one or more external circuits.

[0047] All combinations of the aforementioned and additional concepts discussed herein (where such concepts are not contradictory) are intended to be part of the subject matter disclosed herein. Terms expressly used herein, which may also appear in any disclosure incorporated by reference, should be given meanings that most coincide with the specific concepts disclosed herein.

[0048] The drawings are for illustrative purposes only and are not intended to limit the scope of the subject matter described herein. The drawings are not necessarily to a fixed scale, and in some cases, different aspects of the subject matter disclosed herein may be exaggerated or enlarged in the drawings to facilitate understanding of different features.

[0049] The entire application (including the cover page, title, headings, background, abstract, brief description of drawings, detailed description, implementation forms, summary, figures, appendices, etc.) illustrates various examples of how the implementation forms can be put into practice. The advantages and features of the application are merely representative samples of the implementation forms and are not exhaustive and / or exclusive. Rather, they are presented to aid in the understanding and teaching of the implementation forms and are not representative of all implementation forms. Thus, some aspects of the disclosure are not discussed herein. The inability to provide alternative implementation forms for particular parts of the innovation, or the possibility that further undescribed alternative implementation forms may be available for some, should not be considered to exclude such alternative implementation forms from the scope of the disclosure. It will be understood that many of these undescribed implementation forms incorporate the same principles of the innovation, and others are equivalent. Therefore, it should be understood that several implementation forms may be available, and that functional, logical, operational, organizational, structural, and / or topological modifications can be made without deviating from the scope and / or spirit of the disclosure. Thus, all examples and / or implementations are considered non-limiting throughout this disclosure.

[0050] Furthermore, except for the purpose of reducing space and repetition, no inferences should be drawn regarding these implementations discussed herein in relation to those not discussed herein. For example, the logical and / or topological structure of any combination of any program components (component collections), any set of current features as described in other components and / or drawings and / or as a whole, should be understood to be not limited to a fixed operational order and / or arrangement, but rather any disclosed order is illustrative, and all equivalents, regardless of order, are contemplated by this disclosure.

[0051] Various concepts can be embodied in one or more ways, and at least one example of these is provided. The actions performed as part of a method can be ordered in any suitable way. Thus, while shown as sequential actions in an exemplary implementation, it is possible to construct implementations in which actions are performed in a different order than exemplified, including the simultaneous execution of several actions. In other words, it should be understood that such features may be limited not necessarily to a specific order of execution, but rather to any number of threads, processes, services, servers, etc., that can be executed in accordance with this disclosure, such as sequentially, asynchronously, together, in parallel, simultaneously, synchronously, etc. Thus, some of these features may be mutually contradictory in that they cannot coexist simultaneously in a single implementation. Similarly, some features may be applicable to one aspect of the innovation and not to others.

[0052] In addition, this disclosure may include other innovations not currently described. The applicant reserves all rights in such innovations, including the right to implement such innovations and to file additional applications, continuations, continuations, divisions, etc., therewith. Thus, it should be understood that the merits, implementations, examples, functions, features, logical, operational, organizational, structural, topological, and / or other aspects of this disclosure should not be considered as limitations to the disclosure or to equivalents to the implementations as defined by the implementations. Depending on the specific desires and / or characteristics of individual and / or corporate users, database configurations and / or relational models, data types, data transmission and / or network frameworks, syntax structures, etc., various implementations of the technologies disclosed herein can be implemented to allow for a great deal of flexibility and customization as described herein.

[0053] All definitions as defined and used herein should be understood to govern beyond dictionary definitions, definitions in literature incorporated by reference, and / or the ordinary meanings of the defined terms.

[0054] In this specification and in its implementations, the indefinite articles "a" and "an" should be understood to mean "at least one" unless explicitly stated otherwise.

[0055] In this specification and in its implementations, the phrase “and / or” should be understood to mean “either or both” of the elements thus combined, i.e., elements that exist jointly in some cases and independently in others. Multiple elements enumerated by “and / or” should be interpreted in the same way, i.e., “one or more” of the elements thus combined. Other elements may exist at will, whether related to or unrelated to these specifically identified elements, in addition to those specifically identified by the “and / or” clause. Thus, as a non-restrictive example, a reference to “A and / or B” when used in conjunction with open-ended wording such as “includes” may refer to “A” only (optionally including elements other than “B”) in one implementation, to “B” only (optionally including elements other than “A”) in another implementation, to both “A” and “B” (optionally including other elements) in yet another implementation, and so on.

[0056] In this specification and in its implementations, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as including multiple or list elements, and optionally, additional unlisted items (i.e., including at least one, but also including more than one). Only terms clearly indicated in the opposite way, such as “one only” or “exactly one,” or, in its implementations, “consisting of,” shall refer to including exactly one of multiple or list elements. In general, the term “or” as used herein shall be interpreted only when preceded by terms of exclusivity, such as “either,” “one of,” “one only,” or “exactly one,” to indicate an exclusive choice (i.e., “one or the other, but not both”). “Essentially consisting of” shall, when used in its implementations, have its ordinary meaning as it is used in the field of patent law.

[0057] As used herein and in its implementations, the phrase “at least one” should be understood to refer to a list of one or more elements, meaning at least one element selected from any one or more elements in the list of elements, but not necessarily including at least one of each of the elements specifically enumerated in the list of elements, nor excluding any combination of elements in the list of elements. This definition also makes it possible that elements other than those specifically identified in the list of elements referred to by the phrase “at least one” may exist at will, whether related or unrelated to these specifically identified elements. Therefore, as a non-restrictive example, "at least one of A and B" (or, equally, "at least one of A or B", or equally, "at least one of A and / or B") can mean, in one implementation, that it contains at least one A of any choice, more than one, but no B (or any element other than B); in another implementation, that it contains at least one B of any choice, more than one, but no A (or any element other than A); and in yet another implementation, that it contains at least one A of any choice, more than one, and also at least one B of any choice (or any other element). [Explanation of Symbols]

[0058] 100 Power Systems 101A enclosure 101B enclosure 102A Power String Module 102B Power String Module 104A Energy Module 104B Energy Module 106A Conversion Module 106B Conversion Module 108A High Voltage DC / DC Converter 108B High Voltage DC / DC Converter 110A Ultra-High Voltage DC / DC Converter 110B Ultra-High Voltage DC / DC Converter 302 Voltage Source 304 Power Converter 306 Power Converter 400 Power / Sink 402 Energy Module 404 Conversion Module 406 Battery Pack 408 Battery Management System 410 Switch 412 High Voltage DC / DC Converter 414 BMS Regulator 416 Ultra-high voltage DC / DC converter 418 Battery Power String Controller 502 Energy Module 504 Conversion Module 601 cabinet 602 Low Voltage Bundle 604 Coolant Inlet Port 606 Power String Module 608 Coolant Outlet Port 610 Ventilation holes 611 HV+ terminal 612 HV-Terminal 614 HVAux+ terminal 616 HVAux- terminal 618 Negative manual service disconnect 620 Positive manual service disconnect 622 Grounding studs 623 Power String Management Components 624 Conversion parts 626 Battery Pack 628 Ultra-high voltage DC / DC converter 630 Low-voltage distribution block 632 Regulator 634 Ethernet Converter 636 Electronic control unit 638 Insulation monitoring device 640 Current Sensor 642 fuses 644 High-Voltage Busbar 646 diodes 648 High Voltage DC / DC Converter 650 Battery Management System 652 Voltage Transducer 654 resistor 656 Contactor 702 Energy Module 704 Conversion Module 706 Cooling System 708 High-voltage interconnect 710 Low-voltage components 712 MT Coolant Loop 714 Housing / Support Structure 715 Isolation Switch 716 LT Coolant Loop 718 HV I / O 720 Blocking Grid 802 Power String Module 804 Housing / Support Structure 806 Electrical Cabinet 808 Blocking Grid 810 Cooling System 812 converter 814 Low-voltage components 816 MT Coolant 818 Isolation Switch 820 HV I / O 822 LT Coolant 900 Power Systems 902 Power String Module 904 Blocking Grid 906 DC Link Disconnect 908 Thermal Management System Tower Disconnect 910 Computing Module 912 Under-deck routing channel 914 Isolation Switch

Claims

1. The casing and (1) an energy module including a battery pack contained within the housing and configured to provide an initial voltage, (1) A conversion module included in the housing, (2) comprising a high-voltage DC / DC converter and an ultra-high-voltage DC / DC converter, wherein the conversion module is configured to receive the initial voltage and output a converted voltage using the high-voltage DC / DC converter and the ultra-high-voltage DC / DC converter, A device including a device.

2. The apparatus according to claim 1, wherein the high-voltage DC / DC converter is configured to receive the initial voltage and generate an intermediate voltage, and the ultra-high-voltage DC / DC converter is configured to receive the intermediate voltage and generate the conversion voltage.

3. The apparatus according to claim 1, wherein the housing is a single housing.

4. The apparatus according to claim 1, wherein the housing is configured to protect the proper orientation of the energy module and the conversion module.

5. The apparatus according to claim 1, wherein the energy module and the conversion module are electrically coupled and arranged within the housing such that one or more creepage distance requirements or spatial distance requirements are met.

6. The energy module is a first energy module, the conversion module is a first conversion module, the first energy module and the first conversion module are included in a first power string module included in the housing, and the device is The second energy module, The apparatus according to claim 1, further comprising a second conversion module, wherein the second energy module and the second conversion module are included in a second power string module included in the housing.

7. The apparatus according to claim 6, wherein the first power string module is located in a first housing and the second energy module is located in a second housing.

8. The enclosure is an apparatus enclosure, the energy module is a first energy module, the conversion module is a first conversion module, the first energy module and the first conversion module are included in a first power string module, the first power string module is located inside the first enclosure, and the apparatus is, The second energy module, The present invention further includes a second conversion module electrically coupled to the second energy module, wherein the second energy module and the second conversion module are arranged within a second housing. The apparatus according to claim 1, wherein the first housing and the second housing are arranged inside the apparatus housing.

9. The first energy module and the first conversion module are included in a first power string module located within the first housing. The second energy module and the second conversion module are included in a second power string module located within the second housing. The apparatus according to claim 8, wherein the first housing and the second housing are removably arranged within the apparatus housing, and the first power string module and the second power string module are selectively removable from the apparatus.

10. The steps include providing an initial voltage via a first module contained within the enclosure, The first DC / DC converter included in the housing receives the initial voltage and generates an intermediate voltage, The second DC / DC converter included in the housing receives the intermediate voltage and generates a conversion voltage, Methods that include...

11. The method according to claim 10, wherein the housing is included in a diesel / battery hybrid vehicle.

12. The method according to claim 11, wherein the diesel / battery hybrid vehicle is one of a mining hole truck, a locomotive, or a ship.

13. The method according to claim 10, wherein the first module is a first energy module comprising one or more battery packs configured to generate the initial voltage, and one or more battery management systems configured to selectively connect and disconnect the one or more battery packs.

14. The method according to claim 13, wherein the first DC / DC converter and the second DC / DC converter are included in a first conversion module, the first conversion module further includes a switch, a battery management system regulator, and a battery power string controller, and the first conversion module is configured to receive the initial voltage and generate the conversion voltage.

15. It is a power system, Includes a high-voltage routing channel and a power supply configured to be electrically coupled to the power system and generate power, the power supply is Multiple energy modules configured to generate an initial voltage, A plurality of conversion modules electrically coupled to each of the energy modules of the plurality of energy modules, each of which is configured to receive the initial voltage and generate a conversion voltage, Includes, Each energy module and coupled conversion module defines the power string modules of multiple power string modules. Each power string module is located within the enclosure of multiple enclosures. Each power string module is electrically coupled to the high-voltage routing channel. Power system.

16. The power system according to claim 15, wherein the plurality of housings are detachably coupled to the power supply, and the plurality of power string modules are selectively detachable from the power supply.

17. The aforementioned multiple energy modules are Multiple battery packs configured to generate the initial voltage, One or more battery management systems configured to be operably coupled to the plurality of battery packs and to selectively engage the plurality of battery packs, The power system according to claim 15, further comprising:

18. The aforementioned multiple conversion modules are A switch configured to electrically engage a conversion module with a corresponding energy module, Multiple DC / DC converters configured to receive the initial voltage and generate the conversion voltage, A battery management system regulator configured to adjust one or more battery management systems of the corresponding energy module, A battery power string controller configured to control the battery management systems of at least one of the plurality of battery packs or the corresponding energy modules, It further includes, The energy module and the conversion module are arranged within the housing such that one or more creepage distance requirements or spatial distance requirements are met. The power system according to claim 17.

19. The power system according to claim 15, wherein each of the plurality of power string modules is located in the respective housing of the plurality of housings and coupled to the high-voltage routing channel, so that each power string module can be removed and replaced within the power system by removing and replacing one or more housings of the plurality of housings.

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