Electric Machine with Hybrid Energy Storage

Abstract

An electric machine having a first energy consumption unit and a second energy consumption unit, wherein the first energy consumption unit requires a higher-power energy source and the second energy consumption unit requires a lower-power energy source; the machine further comprises a first energy storage device and a second energy storage device, wherein the first energy storage device has a higher power output than the second energy storage device, the first energy storage device is configured to supply power to the first energy consumption unit, and the second energy storage device is configured to supply power to the second energy consumption unit, the first energy storage device is connectable to a charger for charging, the first energy storage device takes less time to reach a maximum charge state than the second energy storage device, and the first energy storage device is configured to supply power directly to the first energy consumption unit.

Description

[Technical field]

[0001] The present invention relates to an electric machine comprising a first energy store and a second energy store.Furthermore, the present invention relates to a method for configuring an electric machine. [Background technology]

[0002] Various electric machines are provided with a rechargeable energy storage as a power source. Providing a battery to store energy is the preferred choice for applications that are not always directly powered by the power grid but require power for operation.

[0003] One example is the Battery Electric Vehicle (BEV). However, unlike diesel or gas vehicles, the charging time of a BEV is roughly equal to its autonomy (discharge time), which can range from 30 minutes to several hours. Hybrid solutions are preferred in applications where a vehicle is required at high availability, but in that case the vehicle can no longer be fully electric. Summary of the Invention [Problem to be solved by the invention]

[0004] Typically, electric vehicles, such as automated guided vehicles (AGVs), are provided with a rechargeable battery pack as a power source. An electric vehicle can be configured to operate with a battery pack that includes multiple batteries. Commonly used batteries are lead-acid batteries or lithium-ion batteries. Typically, lead-acid batteries must be fully charged, and a drawback is that they have a relatively long charging time. Long charging times can result in long non-productive times for the electric machine (e.g., electric vehicle), which can result in a significant loss of efficiency.

[0005] Typically, in a factory or e-commerce warehouse, material handling or transport of goods needs to be performed 24 hours a day, 7 days a week. The use of electric forklifts or automated guided vehicles (AGVs) instead of warehouse attendants makes such operations more feasible. These small and medium-sized vehicles need to operate fully autonomously with minimal unproductive time. In this respect, how to charge AGVs and how to manage energy becomes crucial to increase productivity. Industrial indoor applications (forklifts, AGVs) require high availability and zero emissions, which necessitates fast charging.

[0006] The very large power required to charge within a few minutes requires the battery dimensions to be rather large. To obtain one hour of autonomy, the battery is cycled about 20 times a day, which may lead to rapid deterioration of the battery. In AGVs, recharging conventional batteries (lead-acid type) takes a significant amount of time (more than 20% of the total duration). The charging duration therefore impacts the overall productivity of the plant, factory or warehouse.

[0007] For example, for lead-acid AGVs, the percentage of time that the vehicle is stopped for charging is typically more than 20 percent, or even as much as 40 percent. For example, within an 8-hour period, the vehicle is stopped for charging for around 3 hours and driven for around 7 hours. To solve this problem, in some cases, 20% to 30% additional AGVs are used, but this is costly and typically difficult to operate. In addition, there is typically limited floor space in the plant, and this limited floor space is blocked by stopped vehicles. With around one-quarter of the vehicles being charged at any one time, multiple chargers may be required. Thus, adding additional AGVs is an overall costly and inefficient solution.

[0008] The charging time of traditional solutions is slow, which tends to reduce the productivity of electric machines (e.g., vehicles). In addition, the batteries in electric vehicles are very large in size, which makes the vehicle bulky, heavy, and expensive. In addition, the batteries may degrade prematurely, which may lead to high expected operating expenses (OPEX). Alternatively, charging while performing operating operations (e.g., loading and unloading) may cause overvoltage issues for the energy source. Also, in the event of a depleted battery, a back-up energy source may not be available.

[0009] Improved designs of electric machines are needed to address at least one of the above-mentioned shortcomings.

[0010] It is an object of the present invention to provide a method and system that overcomes at least one of the above mentioned disadvantages.

[0011] Additionally or alternatively, it is an object of the present invention to provide an electric machine with improved operating efficiency.

[0012] Additionally or alternatively, it is an object of the present invention to provide an electric machine having shorter intervals between charging times.

[0013] Additionally or alternatively, it is desirable to reduce the non-productive time of an electric machine. [Means for solving the problem]

[0014] In order to achieve the above objectives, the present invention provides an electric machine having a first energy consumption unit and a second energy consumption unit, wherein the first energy consumption unit requires a higher-power energy source and the second energy consumption unit requires a lower-power energy source, the machine further comprising a first energy storage device and a second energy storage device, the first energy storage device has a higher power output relative to the second energy storage device, the first energy storage device is configured to supply power to the first energy consumption unit and the second energy storage device is configured to supply power to the second energy consumption unit, the first energy storage device is connectable to a charger for charging, the time required to reach a maximum state of charge in the first energy storage device is shorter than that of the second energy storage device, and the first energy storage device is configured to directly supply power to the first energy consumption unit.

[0015] According to the invention, a fast charging is provided in order to require fewer vehicles. This saves space, for example, on the factory floor. Furthermore, the energy transferred to the second energy storage device (e.g., battery) does not need to be returned to the first energy storage device (e.g., ultracapacitor), which reduces losses. Furthermore, the drive power does not need to be transferred via DC / DC, which reduces losses. A small DC / DC converter may be sufficient, for example, to drive auxiliary systems. Furthermore, no voltage regulator is required for the on-board load. For example, the ultracapacitor may be made smaller, which may save space. The battery can automatically back up the ultracapacitor (due to the DC / DC converter topology). Furthermore, the first energy storage device does not require a dedicated charging time, since it can be charged during operation and operation while stopped. Furthermore, the energy storage system is directly compatible (size, weight, voltage, energy) with existing hardware (e.g., AGVs traditionally powered by lead-acid batteries), so it can be retrofitted. Advantageously, the battery or the first energy storage device (e.g., ultracapacitor) does not need to be oversized. Furthermore, it is possible to avoid an increase in charging time or the need to add an additional charger.

[0016] Charging time of electric machines can be seen as a bottleneck for improving overall efficiency, productivity, etc. in various applications. The percentage of time that a vehicle is stopped for charging can be significantly reduced, e.g., to less than 5 percent or even closer to 1 percent. Also, minimizing the downtime for charging can reduce the number of electric machines (e.g., vehicles) and the number of chargers required. Reducing downtime for charging has a significant impact on the chain of events in which electric machines are used.

[0017] The present invention can provide an energy storage solution (hybrid storage) that can be charged in minutes and give the application an autonomy 10 to 20 times longer than the charging time, with the main objective of maximizing production time and minimizing charging time.

[0018] Also, optionally, the energy capacity of the first energy storage device may be lower relative to the second energy storage device.

[0019] Optionally, the first energy storage device and the second energy storage device may also be provided such that they can be connected to a charger for charging.

[0020] Also, optionally, the first energy storage device may comprise one or more supercapacitors and the second energy storage device may comprise one or more batteries.

[0021] According to the invention, a first energy storage device can be quickly charged, which is used to power a first energy consumer (e.g., for driving propulsion of an electric vehicle, for operating a tool at high power, etc.). A second energy storage device (e.g., a battery) can be used for auxiliary systems (e.g., on-board electronics, communication units, actuators, material handling, cooling, heating, etc.). The energy of the first energy storage device is consumed by distance (per unit of displacement distance), whereas the energy of the second energy storage device is consumed per unit of time. The first energy storage device can be embodied, for example, as an ultracapacitor. Since the energy capacity / content of an ultracapacitor is relatively small, the ultracapacitor is designed and dimensioned as small as possible for a specific application.

[0022] It should be noted that there are various examples of the embodiment of the first energy store, which may be embodied as one or more supercapacitors or ultracapacitors, however, other high power storage devices allowing fast charging may also be used, for example flywheels or pneumatic or hydraulic. For example, a flywheel is an electromechanical device, where the energy is input via an electric motor and recovered via a generator (usually the same unit as the motor).

[0023] Also, optionally, the first energy storage device and the second energy storage device may be configured such that when a voltage of the first energy storage device falls below a voltage threshold, the second energy storage device automatically provides a backup power source to power the first energy storage device.

[0024] For example, the second energy storage device (e.g., a lithium-ion battery) can be configured to act as a backup and provide energy to drive the AGV when the voltage of the first energy storage device (e.g., UCap) falls below a certain threshold. In this way, the first energy storage device (e.g., UCap) is charged from the second energy storage device (e.g., a battery).

[0025] Optionally, the electric machine may also include a circuit element disposed between the first energy storage device and the second energy storage device, the circuit element being configured to pass current in only one direction, from the second energy storage device to the first energy consumer.

[0026] By providing the circuit element, the electric machine can realize a backup system without requiring a complex control system and can improve the reliability of the backup system. The second energy storage device can automatically provide a backup energy source by current passing through the circuit element when necessary.

[0027] Also, optionally, the circuit element is a component that allows current to flow in one direction. The circuit element may be configured to act like a one-way valve for current.

[0028] Also, optionally, a diode is disposed between the second energy storage device and the first energy storage device, and when the second energy storage device provides a backup power source to the first energy consumption unit, current flows from the second energy storage device to the first energy consumption unit through the diode.

[0029] The voltages of the second energy storage device and the first energy storage device may be different. If the charge state in the first energy storage device is depleted / empty, the second energy storage device can be configured to automatically take over and provide the energy source needed to run in limp mode to the nearest charger. In such a case, no additional converter is required. The voltage of the first energy storage device can be equal to the voltage of the second energy storage device (diode, 0.4V difference). Thus, as long as there is no load on the first energy storage device, there is no current flowing through the first energy storage device. The current flows to the load.

[0030] In the case of an electric vehicle, the motor drive can accommodate the voltage window of the first energy storage device, which can be a relatively large voltage window (e.g., between 30V and 60V). This is not a problem for the motor drive, but can be a problem for the on-board electronics, and is accommodated by arranging a DC-DC converter between the first and second energy storage devices. For example, in a backup system, the second energy storage device does not charge the first energy storage device. Current can be transferred directly from the second energy storage device to the propulsion of the vehicle. The second energy storage device does not charge the first energy storage device, but takes control of the propulsion. However, for example, if a DC-DC converter (or a bidirectional DC-DC converter) is additionally used, the first energy storage device can be charged. In this way, full power may be provided when acceleration of the vehicle is required.

[0031] The voltages of the first and second energy storage devices may be matched and adapted (designed and adjusted) so that the second energy storage device automatically backs up the first energy storage device when the first energy storage device is almost empty. In this way, diodes can be employed instead of DC-DC converters, resulting in a cheaper design. Diodes are relatively cheap devices (much cheaper than DC-DC converters). The lower limit voltage can be slightly lower than the reference voltage of the second energy storage device, and can be configured to automatically back up propulsion when the second energy storage device has a sufficient charge.

[0032] If the circuit element is a diode, a simple design can provide an effective and reliable backup energy source when needed. For example, a unidirectional converter can be placed in parallel with the diode.

[0033] It should be noted that the diode may be replaced by any component (eg, an electrically or electronically controlled circuit element) that, during operation, acts like a diode by conducting current primarily in one direction.

[0034] Also, optionally, the circuit element is an electronically controlled switch configured to allow current to flow in only one direction from the second energy storage device to the first energy consumption unit when the second energy storage device provides backup power to the first energy consumption unit.

[0035] Also optionally, the circuit elements are solid state controlled switches. Advantageously, electrical losses due to voltage drops are reduced or prevented.

[0036] Optionally, a direct current to direct current (DC / DC) converter is disposed between the first energy storage device and the second energy storage device, the DC / DC being capable of passing current from at least the first energy storage device to the second energy storage device.

[0037] Also, optionally, the DC / DC converter is unidirectional.

[0038] Optionally, the DC / DC converter is also bidirectional.

[0039] For example, a DC / DC converter and diodes are arranged between a first energy storage device (e.g., a UCap) and a second energy storage device (e.g., a lithium-ion battery) to transfer energy from the first energy storage device to the second energy storage device and from the second energy storage device to the first energy storage device, respectively. The DC / DC converter can be a simple unidirectional step-down converter to provide energy from the first energy storage device to the second energy storage device. A freewheeling diode can also provide automatic backup from the second energy storage device to the first energy storage device.

[0040] Also optionally, the electric machine is an electric vehicle, the first energy consumer is a propulsion system in the electric vehicle and the second consumer comprises at least one auxiliary system in the vehicle.

[0041] For example, the present invention can realize an ultra-fast hybrid energy storage device that builds a high-speed and long-life hybrid pack for AGVs to improve production efficiency. For example, the hybrid storage device for AGVs is equipped with ultracapacitors (e.g., Ucaps, LiCap, etc.) and lithium-ion batteries to meet the energy requirements. In this way, the first energy storage device (e.g., ultracapacitors) always supplies energy to drive the AGV, and when there is surplus energy, it is used to charge the second energy storage device (e.g., lithium-ion batteries) during driving.

[0042] Meanwhile, a second energy storage device (e.g., a lithium-ion battery) is used to power the on-board electronics and to perform loading and unloading of the load. Other auxiliary systems can be, for example, units for communication between the AGV and remote locations (e.g., servers), lighting, speakers, air conditioning, heating, cooling, wired or wireless communication, etc.

[0043] Optionally, the electric vehicle is also configured to recover braking energy in a first energy storage device. Lead acid batteries have limitations on the recovery of braking energy, but when an ultracapacitor or the like is used as the first energy storage device, there are no such limitations.

[0044] Also, optionally, the ultracapacitor is sized based on at least one of the traction power or the electric braking power of the electric vehicle.

[0045] Also optionally, the electric machine is an electric tool, the first consumer comprising at least one high power subsystem of the tool and the second consumer comprising at least one low power auxiliary subsystem of the tool.

[0046] The present invention provides an electric machine that is flexible and has very little downtime. The present invention is not limited to applications in mobility such as vehicles (e.g., AGVs performing operations such as loading and unloading). The present invention can also be applied to various examples and applications that require energy storage to perform operations and tasks, such as, for example, power tools such as forklifts, mobile high-pressure water cleaners, etc. The tools can be mobile or stationary, for example, when in use. For example, an automatic stacker crane is fixed at the installation site.

[0047] A high pressure washer with a conventional battery may have to be charged for a long time (e.g., overnight) in order to operate (e.g., during the day). The present invention allows for quick charging (e.g., about 15 minutes), which allows for a reduction in batteries and increases flexibility. Even under very high loads, the electric machine may be fully charged in only a limited time (e.g., about 15 minutes), which may allow another shift (e.g., 3-4 hours) of operation.

[0048] According to the present invention, charging times can be significantly reduced: ultracapacitors allow relatively fast charging, for example requiring charging times of less than 10 minutes, preferably less than 5 minutes, even more preferably less than 3 minutes, e.g. 2 minutes.

[0049] Also optionally, the vehicle includes a controller configured to perform at least power management, the controller determining a predetermined route for the vehicle to travel between the first charging point and the second charging point, determining a full charge state at the first charging point at which the first energy storage device is fully charged, determining a total energy required for the vehicle to travel from the first charging point to the second charging point, determining surplus energy based on the full charge state and the total energy, and operating the machine to charge the second energy storage device using the surplus energy during at least a portion of the travel between the first charging point and the second charging point.

[0050] Also, optionally, the vehicle is configured to perform loading and unloading operations between at least one of the first charging point or the second charging point, the loading and unloading operations being performed by auxiliary subsystems in the vehicle powered by the second energy storage device.

[0051] Loading, unloading or other material handling can be performed using one or more actuators or manipulators.

[0052] Also, optionally, the first energy storage device has a power that is at least five times, preferably at least ten times, that of the second energy storage device, and the second energy storage device has an energy capacity that is at least twice that of the first energy storage device.

[0053] The amount of power that can be supplied and absorbed by the first energy storage device may be significantly greater than the second energy storage device.

[0054] For example, the first energy storage device has a low energy capacity (e.g., 0.5 kWh) and a high output energy (e.g., 12 kW), and the second energy storage device has a high energy capacity (e.g., 1.5 kWh) and a low output energy (e.g., 500 W).

[0055] Also, optionally, the first energy storage device is configured to be fully charged in less than 15 minutes, preferably less than 10 minutes, and more preferably less than 5 minutes.

[0056] The charging time required to fully charge the first energy storage device may be significantly shorter than the second energy storage device.

[0057] Also optionally, the first energy storage device comprises at least one of a flywheel, a hydraulic energy storage device, or a compressed air energy storage device. Other mechanisms for rapidly storing relatively large amounts of energy may be used.

[0058] According to one aspect, the present invention provides a method of configuring an electric machine, the method comprising the steps of providing a first energy consumer and a second energy consumer, the first energy consumer requiring a higher power energy source and the second energy consumer requiring a lower power energy source, and providing a first energy storage device and a second energy storage device, the first energy storage device being higher power relative to the second energy storage device, the first energy storage device being configured to provide power to the first energy consumer and the second energy storage device being configured to provide power to the second energy consumer, the first energy storage device being connectable to a charger for charging. wherein the first energy storage device takes less time to reach a maximum state of charge than the second energy storage device, the first energy storage device is configured to directly supply power to the first energy consumer, the first energy storage device and the second energy storage device are configured such that when a voltage of the first energy storage device falls below a voltage threshold, the second energy storage device automatically provides a backup power source to power the first energy storage device, and the electric machine includes a circuit element disposed between the first energy storage device and the second energy storage device, the circuit element configured to pass current in only one direction from the second energy storage device to the first energy consumer.

[0059] Longer charging times may result in longer non-productive times and thus a loss of efficiency. According to the invention, the non-productive times can advantageously be reduced by significantly reducing the charging duration. Reducing the non-productive times requires fast charging, which can be achieved by a semi-hybrid. For example, the electric machine can be an electric vehicle including ultracapacitors for the supply of power for propulsion and traction, which can be charged very quickly, and lithium-ion batteries for the transfer of energy to auxiliary systems, which require longer charging time intervals. The non-productive times can be reduced to zero by charging the first energy storage device while the vehicle is stopped, for example for material handling, which is independent of the charging process, since it is powered by a second energy storage device.

[0060] According to one aspect, the present invention relates to a hybrid energy storage system that includes a higher power energy source and a lower power energy source.

[0061] It should be noted that the circuit element may be a diode, a two-terminal electronic component that conducts current primarily in one direction. The circuit element may provide asymmetric conductance. Alternatively, the circuit element may be a switch that is controlled to conduct current primarily in a single direction and block current in the reverse direction. To accomplish this, the circuit element may have a low resistance (ideally zero) in one direction and a high resistance (ideally infinite) in the other direction.

[0062] For example, a diode may be configured to begin conducting electricity only when a certain threshold or cut-in voltage is present in the forward direction (ie, the direction in which current can flow or pass).

[0063] It should be noted that the circuit elements may take a variety of forms and implementations. In addition to the various diodes that may be used, alternative forms may also be used, such as electronic components that act as diodes.

[0064] In other exemplary embodiments, the circuit element may be a contactor, which is an electrically controlled switch used to switch a power circuit to conduct electricity in a forward direction and block current flow in the reverse direction.

[0065] In this specification, the term "supercapacitor" may refer to an ultracapacitor (ucap), an electric double layer capacitor (EDLC), or the like.

[0066] Electric vehicles can be embodied in many different ways, such as AGVs, tools, cleaning machines, forklifts, and automated stacker cranes, electric cars, electric buses, ferries, electric trucks, metro, light rail transport, etc. Electric machines can be used in assembly plants, e-commerce warehouses, automotive and logistics (ports and airports), parcel, courier, delivery services and distribution centers, healthcare industry, food and beverage industry, aerospace industry, and manufacturing industry.

[0067] It should be noted that any aspect, feature, or option for the electric machine applies equally to the described systems and methods, and any one or more of the above aspects, features, and options may be combined. [Brief description of the drawings]

[0068] [Figure 1] FIG. 1 is a schematic diagram of one embodiment of a machine. [Diagram 2] FIG. 1 is a schematic diagram of one embodiment of a machine. [Diagram 3] FIG. 1 is a schematic diagram of one embodiment of a machine. [Figure 4A] FIG. 1 is a schematic diagram of one embodiment of a machine. [Figure 4B] FIG. 1 is a schematic diagram of one embodiment of a machine. [Diagram 5] FIG. 2 is a schematic diagram of an embodiment of a vehicle route. [Figure 6] FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0069] The invention will be further explained on the basis of exemplary embodiments shown in the drawings, which are given by way of non-limiting example and which are merely schematic representations of embodiments of the invention.

[0070] FIG. 1 is a schematic diagram of an embodiment of an electric machine 1. The electric machine is provided with a first energy consumer and a second energy consumer. In this example, the electric machine is embodied as an AGV, but it may be other devices (e.g. tools such as a high-pressure washer, elevator, crane, etc.). The first energy consumer requires an energy source with a higher power output, and the second energy consumer requires an energy source with a lower power output. Furthermore, the machine is provided with a first energy storage device 3 and a second energy storage device 5. The first energy storage device 3 has a higher power output compared to the second energy storage device 5. In this example, the first energy storage device 3 is embodied as one or more ultracapacitors, and the second energy storage device 5 is embodied as one or more batteries. The first energy storage device 3 is configured to supply power to the first energy consumer, and the second energy storage device 5 is configured to supply power to the second energy consumer. The first energy storage device 3 is connectable to a charger for charging. Furthermore, the first energy storage device 3 is configured to reach its maximum state of charge in a shorter charging time than the second energy storage device 5. Furthermore, the first energy storage device 3 is configured to directly supply power to the first energy consumer.

[0071] The charger can directly charge the ultracapacitor. For example, in an electric machine, the charger can charge the ultracapacitor to the maximum allowable voltage in less than 5 minutes, more preferably in less than 3 minutes. The charged ultracapacitor can drive the electric machine (such as a vehicle or a tool). Meanwhile, the electric machine may be provided with auxiliary systems that require power, such as on-board electronics, actuators for loading and unloading, etc. For example, the present invention employs a semi-hybrid energy storage system, including an ultracapacitor and a battery (e.g., lithium ion) that can be integrated into the electric machine. The ultracapacitor can be configured as a power source for driving the vehicle and can be charged directly (e.g., in less than 5 minutes), and the battery can be configured to control other auxiliary systems (e.g., on-board electronics, loading and unloading, etc.).

[0072] FIG. 2 is a schematic diagram of an embodiment of the machine 1, in particular the energy storage system 7. The energy storage system 7 of the machine 1 is provided with a first energy storage device 3 and a second energy storage device 5, with a DC-DC converter 8 arranged between them. The transfer of energy from the first energy storage device 3 (e.g. an ultracapacitor) to the second energy storage device 5 (e.g. a battery) can be performed via the DC-DC converter 8. The remaining energy (in the first energy storage device 3) can be transferred to the second energy storage device 5, for example, for use on a shorter route traveled by the vehicle. If the energy in the first energy storage device 3 is exhausted (or if the device 3 reaches a minimum threshold voltage), it will no longer be possible to drive the vehicle using the first energy storage device 3. In such a case, if the second energy storage device 5 has a sufficient state of charge (SoC), the energy can be passed either via a diode or via a bidirectional DC-DC converter 8. In a backup scenario, energy is transferred from the second energy storage device 5 to the first energy storage device 3, which then drives the vehicle.

[0073] In this example, a diode is a circuit element arranged between the first and second energy storage devices, which is configured to allow current to flow only in one direction from the second energy storage device to the first energy consumer. However, other types of circuit elements can be used according to the invention. The circuit element can be an electronic or electromechanical device configured to conduct current in one direction. The circuit element (e.g., a diode) can be configured to automatically allow current to flow mainly in one direction. However, it is also possible for the circuit element to be manually or automatically controlled. Figure 3 is a schematic diagram of an embodiment of a machine 1 that can be connected to a charger 9. The charger can be connected to the grid via a connection 11. The charger is further provided with a rectifier and DC / DC converter 13, the output of which is provided to a DC / AC converter 15 for connection to a port 17 for wireless charging of the first energy storage device (in this example an ultracapacitor). An additional converter may be required for wireless charging. Although wireless charging is employed in this example, wired charging (e.g., with less conversion) can also be employed. For this purpose, the electric machine may be configured with an AC / DC converter 19. Furthermore, the output of the DC / DC converter 13 may be connectable to an optional DC / DC converter 21 arranged for connection to a second energy storage device 5 (here a lithium-ion battery).

[0074] The embodiment shown in FIG. 3 shows a schematic example of a hybrid energy storage in an AGV 1 that can be connected to a charger 9. In this example, the UCaps is fully charged in 3 minutes by a 12 kW charger. The energy required by the AGV at the charging point (travel + loading and unloading + power supply to the on-board electronics) is known in advance before the AGV starts traveling on a predefined route. It is calculated whether the energy supplied to the UCaps during charging is sufficient only for the vehicle drive on a complete driving cycle or travel route. If, for example, the length of the route is a drive of more than one hour and the available energy in the UCaps is sufficient only for the drive of the AGV, the power for the on-board electronics and the loading and unloading of the load is provided by the battery. The DC / DC converter 8 arranged between the first energy storage device 3 and the second energy storage device 5 can be disabled. Also, if the selected driving cycle or driving route is short and the energy provided to the UCap during charging is more than sufficient for driving the vehicle in a complete driving cycle or driving route, the excess energy of the UCap can be transferred to the battery via the DC / DC converter 8. In this way, the battery can be periodically charged during the operation of the vehicle. The battery directly supplies power for the on-board electronics and the loading and unloading operations, which require a certain voltage. Furthermore, if the voltage on the UCap drops to its minimum threshold voltage during the operation of the AGV, the battery can take over from the UCap and provide sufficient energy for driving the vehicle in a limp-home state via the freewheeling diode. Furthermore, if the vehicle is stopped due to some unforeseen obstacle or foreign object, the DC / DC converter 8 can be configured to be disabled to ensure that the energy in the UCap is sufficient to complete the driving cycle or driving route and return to the charging point after the removal of the foreign object. Furthermore, since the battery directly powers the on-board electronics and loading / unloading independently of the charging process, if the vehicle stops to load or unload a cargo at certain points during the driving cycle or route, this period can be used to charge the UCap.For example, a goal of energy management is for the UCap to leave the charger fully charged and return with the UCap's charge depleted. In this way, the maximum amount of energy can be transferred during charging. DC / DC converter 8 can be used to achieve this goal by charging the on-board battery.

[0075] Although the above examples have been described with respect to electric vehicles, the invention is also applicable to other applications, such as other tools, high pressure cleaners, cranes, elevators, etc.

[0076] The electric machine may for example be a high-pressure washer with an auxiliary pump (for circulating water), a cooling unit, an electric heating unit, a heater control device, etc., where the high-pressure pump can be considered to correspond to the first energy consumer. If, for example, water spraying is performed only 10% or 20% of the total operating time of the high-pressure washer, then for 80% to 90% of the total time the high-pressure washer is not operating. However, the auxiliary systems (for example the heating unit, the cooling unit and other auxiliary units) continue to operate and consume energy.

[0077] 4A and 4B show schematic diagrams of an embodiment of the machine 1. In the example shown in FIG. 4A and FIG. 4B, the machine 1 is an AGV. However, the electric machine may be embodied as other electric tools. FIG. 4A shows a schematic diagram of a hybrid storage device (UCap and battery) of an AGV and a method of using it. In the embodiment shown in FIG. 4A, a DC / DC converter and a diode 21 between a first energy storage device 3 (e.g., UCap) and a second energy storage device 5 (e.g., a lithium-ion battery) transfers energy from the first energy storage device 3 to the second energy storage device 5 and from the second energy storage device 5 to the first energy storage device 3, respectively. The DC / DC converter 8a is a unidirectional step-down converter that supplies energy from the UCap to the battery. A freewheeling diode provides an automatic backup from the battery to the UCap. FIG. 4B shows a schematic diagram of a hybrid storage device (UCap and battery) of an AGV and a method of using it. In the embodiment shown in Figure 4B, a bidirectional DC / DC converter 8b is placed between the first energy storage device 3 and the second energy storage device 5. The limited use of the DC / DC converter (in time and direction) reduces losses introduced by the DC / DC converter and increases energy efficiency.

[0078] The first energy storage device 3 (e.g., ultracapacitor) can be configured to always drive the propulsion force in normal use of the electric vehicle. Thus, all of the energy for operating the vehicle's drive may be provided by the first energy storage device 3 (this is the case under normal conditions, except for the case where, for example, the ultracapacitor is fully discharged before the vehicle reaches the charging point, after which the second energy storage device 5 (e.g., battery) takes over and provides energy to either the diode 21 or the bidirectional DC / DC converter 8b). In this configuration, the second energy storage device 5 (e.g., battery) operates as a backup. While it is desirable for the first energy storage device 3 (e.g., ultracapacitor) to provide energy for propulsion, in the worst case, when there is not enough energy left in the second energy storage device 5 (e.g., battery), the second energy storage device 5 can take over from the first energy storage device as a backup system.

[0079] As an auxiliary system, the vehicle may load and unload loads. Simultaneous charging and operation (e.g. material handling, loading and unloading) can lead to overvoltages in conventional battery systems. This technical problem often occurs when batteries, for example lead-acid batteries, are used as the energy source. For example, during charging, the voltage can increase (e.g. 29 V instead of the standard value of 24 V), resulting in a voltage of approximately 29 V. To prevent this would mean longer charging times (and therefore longer downtimes), since the on-board electronics would be damaged if they could not cope with the higher voltages. Voltage limiting is a technical solution, but it compromises the economic balance (longer downtimes).

[0080] The present invention solves this problem by separating the power sources for locomotion and auxiliary subsystems such as loading and unloading. For example, an electric vehicle can use ultracapacitors as a power source to drive and charge, and a battery to power the on-board electronics, among other things, to perform auxiliary tasks such as handling operations (e.g., loading and unloading).

[0081] Example numbers illustrating the relationships between the components shown in FIG. 4 are: UCap energy capacity=460Wh, battery=1200Wh, DC / DC=500W, propulsion=3kW, charger power rating=12kW, UCap voltage range=33V to 57V, battery voltage range=30V to 42V.

[0082] For example, there may be no DC converter in the traction line (energy flow). This configuration saves significant costs and reduces losses. Ultracapacitors are high power and the price of the DC converter is determined by the power of the DC converter. Therefore, an ultracapacitor with a converter is more expensive than a battery with a converter. Capacitors are essentially high power devices. So, it is an advantageous design for the case where the ultracapacitor is configured to absorb the charge of the charger and convert it into a large battery, which then supplies power to the drive line. But then there would be two conversions of traction energy, from the ultracapacitor to the battery and from the battery to the traction motor (wheels). The present invention is advantageous in that it avoids one conversion for the main energy flow.

[0083] The electric vehicle may be configured to regenerate braking energy in a first energy storage device. The first energy storage device (e.g., an ultracapacitor) may be sized based on at least one of the traction and propulsion power or the electric braking power of the electric vehicle. In this example, arrow 22a illustrates the traction and propulsion power for driving the vehicle, and arrow 22b illustrates an exemplary energy regeneration via electric braking.

[0084] FIG. 5 is a schematic diagram of an embodiment of a vehicle route 50. The electric machine may be an electric vehicle with a controller configured to provide at least power management. The controller may be configured to determine a predefined route 51 for the vehicle to travel between a first charging point 53 and a second charging point 55. The controller may further be configured to determine a full state of charge, where the first energy storage device 3 is fully charged at the first charging point, determine a total energy required for the vehicle to travel from the first charging point to the second charging point, and determine a surplus energy based on the full state of charge and the total energy. The controller may further be configured to operate the machine to use the surplus energy to charge the second energy storage device 5 during at least a portion of the travel between the first charging point 53 and the second charging point 55. The vehicle may be configured to perform loading and unloading operations between at least one of the first charging point or the second charging point, the loading and unloading operations being performed by auxiliary subsystems of the vehicle powered by the second energy storage device 5.

[0085] Electric vehicles (e.g. AGVs) can be used in different applications, e.g. in plants, factories or warehouses. Line 60 represents the route that the vehicle has to cover. Points 61 indicate the locations where the vehicle has to stop to perform an action, e.g. loading or unloading. Points 63 (green points) represent charging points, locations where the vehicle can stop to charge or to load or unload (performing two functions at the same time: charging + loading-unloading). Points 65 indicate locations where charging of the electric vehicle is possible.

[0086] Figure 6 is a schematic diagram of a graph 100 showing the battery state of charge versus the energy required by the AGV during a driving cycle. At the start of the initial route, the battery state of charge (SoC) is assumed to be 50% and the UCap is empty. The UCap is fully charged by the charger with 460Wh. A total of 297Wh is required for the first driving cycle. Therefore, during the next charging session, the battery is charged with 460Wh-187Wh=273Wh.

[0087] The longest work cycle is expected for charging session 5 (energy required = 707Wh). All the energy in the UCap (460Wh) is needed for towing, and the energy for on-board consumers and loading / unloading (707Wh-460Wh=247Wh) is slowly discharged from the battery.

[0088] This cycle work sequence is considered a realistic worst case scenario for a 16 hour shift, and the battery SoC at the end is higher than at the beginning, proving that the system is completely self-sustaining, i.e. no maintenance charging (and consequent non-productive time) is required.

[0089] Figure 6 shows a table of energy usage. In this example, a DC / DC converter and diodes are placed between the exemplary LiCaps (which have a minimum voltage requirement) and the Li-ion battery to transfer energy from the LiCaps to the battery and from the battery to the LiCaps (when the voltage of the LiCaps reaches a minimum value). The LiCaps can operate from 2.2V to 3.8V. To provide an operating voltage of 33V to 57V, the hybrid device is equipped with 16 LiCap cells in series and 7 LiCap cells in parallel. In addition to the LiCaps, there is a string of 10 Li-ion batteries with voltages between 30V and 42V. The DC / DC converter can be a simple unidirectional step-down converter. Its internal freewheeling diode provides automatic backup to the LiCaps by the battery. The BMS manages the voltage balance of the LiCaps and the battery along with the control of the converter. The diodes prevent the voltage from dropping below the minimum voltage requirement of the LiCaps.

[0090] The energy requirements of the AGV are different for propulsion, loading and unloading (i.e. handling) and powering the on-board electronics. The AGV can operate at a constant speed. The route duration and the energy required for the route can be known in advance. In this example, the ultracapacitors of the AGV can be directly charged in about 3 minutes. The ultracapacitors can store 460Wh of energy. The amount of energy required for propulsion per sub-route can be calculated, which can be separated from the energy required for auxiliary systems (e.g. electronics and handling (i.e. loading and unloading)). Furthermore, the energy requirements of the AGV can be predetermined or estimated. For example, if the ultracapacitors can be fully charged to 460Wh, but the energy required for the trip is 300Wh, 160Wh will remain when the vehicle completes the sub-route. The energy requirements can be based on estimation, for example using historical data. The estimate includes small variations, but additional energy (surplus) remains in the ultracapacitor, which can be transferred to the battery (i.e., charging the battery).

[0091] It is desirable for a vehicle to arrive at a charging point with an ultracapacitor nearly empty, so that it is charged with as much energy as possible. The energy stored in the ultracapacitor is primarily used for propulsion. Therefore, excess energy may be transferred to the battery to prevent it from being depleted. Generally, batteries cannot support fast charging as well as ultracapacitors. Ultracapacitors may have a lower energy density than batteries. However, ultracapacitors can be charged at a much faster rate compared to batteries.

[0092] In an AGV, there may be two energy demands: a primary energy demand for drive / propulsion and a secondary energy demand for auxiliary (sub)systems. An AGV may be configured to run multiple cycles without the need to recharge the batteries, but this is usually considered a long-term process and requires a stop of the AGV. For example, it takes several hours to recharge a lithium-ion or lead-acid battery. Advantageously, the charger allows the AGV to obtain a maximum amount of energy each time it charges the ultracapacitor. For example, since the ultracapacitor is charged to a maximum amount of energy each time it is charged at a charging point, the electric machine can be configured to consume most of the energy stored in the ultracapacitor (e.g., to recharge the next battery that drives the vehicle's propulsion) so that it is somewhat empty when it arrives at the next charging point.

[0093] For example, the ultracapacitor can be used to provide the energy required for propulsion and driving of the vehicle, and the battery can be used to provide the energy required to operate other actuators, handling, on-board electronics, etc. The drive power is relatively high compared to the power required by the on-board electronics. For example, the drive power is 3 kW, while the on-board electronics is 200 W (15 times less). The power for the auxiliary systems (e.g., on-board electronics) may be lower, but the vehicle is sometimes stopped, in which case the energy from the ultracapacitor providing the propulsion energy is not consumed. However, the auxiliary systems may still require energy when the vehicle is stopped. The ultracapacitor can be as small as possible in terms of energy capacity (very low energy density would require a relatively large space). The power density of the ultracapacitor is relatively high.

[0094] Optionally, the first energy storage device (e.g., an ultracapacitor) may be configured to be charged to its maximum amount each time it is charged. The ultracapacitor may be configured to provide traction energy for the longest route while being sized as small as possible. For example, the size may be the smallest size of the ultracapacitor.

[0095] When the AGV is not traveling the longest route, i.e. the longest route that can be known in advance, energy can be transferred from the first energy storage device (e.g. ultracapacitor) to the second energy storage device (e.g. battery), allowing the battery to remain balanced for a longer period of time.

[0096] The energy capacity of the first energy storage device may be sized according to the traction energy required for the longest route of the plurality of consecutive routes.

[0097] Shorter routes do not require all the energy from the ultracapacitors. A route can be defined as a trajectory between two charging locations. For example, if a charging location is not passed through on the route, it may also be considered as a route. Traction or propulsion (driving operation) can be considered as a high-power load. The electric machine comprises a high-power consumer (see first energy consumer) and a low-power consumer (see second energy consumer). The first energy storage device can be configured to supply power to the high-power consumer (e.g. 3 kW) and the second energy storage device can be configured to supply power to the low-power consumer (300 W to 200 W).

[0098] If the route is short, the amount of energy remaining in the first energy storage device (e.g., an ultracapacitor) can be transferred to the battery. The battery can be configured to provide energy to auxiliary systems, such as on-board electronics. For the longest routes, most of the available energy may be provided for propulsion.

[0099] A first energy storage device (e.g., an ultracapacitor) can be charged during material handling. The material handling uses energy from a second energy storage device (e.g., a battery). The first energy storage device may be completely separate from the second energy storage device. Thus, a charger can be advantageously located at the point of material handling to charge the ultracapacitor without affecting the voltage of the second energy storage device (e.g., a battery).

[0100] At the charging point, the vehicle's first energy storage device can be charged with the maximum amount of energy it can store. When the first energy storage device (e.g., ultracapacitor) is depleted (drops to its minimum threshold voltage), the second energy storage device (e.g., battery) can take over and transfer energy to a diode or DC-DC converter.

[0101] In the table, Ecap start indicates the energy stored in the ultracapacitor when the vehicle is started. In this example, the ultracapacitor is fully charged to 460Wh.

[0102] In the table, Ecap end indicates the energy stored in the ultracapacitor when the vehicle arrives and completes its route. For example, the ultracapacitor is preferably discharged to zero so that it is charged with the maximum amount of energy (see Ecap start 460Wh).

[0103] In the table, Ecap needed indicates the amount of energy required to tow or propel the vehicle along the planned route.

[0104] In the table, Ebat needed indicates the amount of energy required by the on-board electronics and material handling along the planned route.

[0105] In the table, E to bat indicates the amount of energy transferred from the ultracapacitor to the battery (energy transfer) when the route is short.

[0106] In the table, E in bat indicates the SoC of the battery after the route is completed.

[0107] In the table, P DC / DC denotes the power transferred between the ultracapacitor and the battery via the DC-DC converter.

[0108] In the exemplary table, information is provided that indicates which route the vehicle will take and how much energy is required. The planned route may include multiple sub-routes between charging points. The routes and sub-routes may be predefined so that the energy requirements are predefined. When the vehicle is traveling along a particular route, the sub-routes may have different energy requirements.

[0109] The vehicle can take different sequences of (sub)routes, and for each subroute the vehicle consumes energy (longer subroutes consume more energy, shorter subroutes consume less energy).

[0110] The maximum energy required to travel along the longest (sub)route can be known (e.g., 700Wh). The ultracapacitors of the vehicle can be configured to provide all of the energy to power the vehicle when it is traveling along the longest route. The amount of energy required to travel along the shortest (sub)route can be known as well. The first energy storage device (e.g., ultracapacitor) can be designed based on this information. For example, the vehicle can be designed to know how many ultracapacitors are needed for the longest route the vehicle will travel, and how much energy the vehicle needs to be charged with to power the vehicle when it travels along the longest route.

[0111] It should be noted that the above-mentioned method may include computer-implemented steps. All the above-mentioned steps may be computer-implemented steps. A computer device may be provided in the embodiment, and the process is executed on the computer device. The invention also extends to a computer program adapted to implement the invention, in particular a computer program on or in a carrier. The program may be in the form of source code or object code, or in any other form suitable for use in implementing the process according to the invention. The carrier may be any entity or device capable of executing a program. For example, the carrier may include a storage medium such as a ROM, e.g. a semiconductor ROM or a hard disk. Furthermore, the carrier may be a carrier capable of transmitting an electric or optical signal, etc., which may be transmitted via an electric or optical cable, or by radio or other means, e.g. via the Internet or the cloud.

[0112] Some of the embodiments may be implemented, for example, using a machine, tangible computer readable medium, or article capable of storing instructions or sets of instructions that, when executed by a machine, can cause the machine to perform methods or operations in accordance with the embodiments.

[0113] Various embodiments may be implemented using hardware elements, software elements, or a combination of both. Examples of hardware elements include processors, microprocessors, circuits, application specific integrated circuits (ASICs), programmable logic devices (PLDs), digital signal processors (DSPs), field programmable gate arrays (FPGAs), logic gates, registers, semiconductor devices, microchips, chipsets, etc. Examples of software include software components, programs, application programs, computer programs, system programs, machine programs, operating system software, mobile apps, middleware, firmware, software modules, routines, subroutines, functions, computer-implemented methods, procedures, software interfaces, application program interfaces (APIs), methods, instruction sets, computing code, computer code, etc.

[0114] The present invention has been described herein with reference to specific examples of embodiments of the present invention. However, it is clear that various modifications, variations, substitutions, and changes can be made without departing from the essence of the present invention. Although features are described herein as part of the same or separate embodiments for clarity and conciseness of description, alternative embodiments including all or some combinations of the features described in these separate embodiments are also envisioned and fall within the scope of the present invention as outlined by the claims. Thus, the specification, drawings, and examples should be regarded as illustrative rather than restrictive. The present invention is intended to embrace all alternatives, modifications, and variations that are within the spirit and scope of the appended claims. Moreover, many of the described elements are functional entities that can be implemented as separate or distributed components or in conjunction with other elements in any suitable combination and location.

[0115] In the claims, reference signs placed between parentheses shall not be construed as limiting the claims. The word "comprising" does not exclude the presence of other features or steps than those listed in a claim. Moreover, the terms "a" and "an" are not limited to "only one" but are instead used to mean "at least one" and do not exclude a plurality. The mere fact that certain measures are recited in mutually different claims does not indicate that a combination of these measures cannot be used to advantage. The following is a summary of the claims as originally filed: [1] An electric machine having a first energy consumer and a second energy consumer, The first energy consumer requires a higher output energy source and the second energy consumer requires a lower output energy source, the machine further comprising a first energy storage device and a second energy storage device, the first energy storage device being higher output relative to the second energy storage device, the first energy storage device being configured to supply power to the first energy consumer and the second energy storage device being configured to supply power to the second energy consumer, the first energy storage device being connectable to a charger for charging, and a time required for the first energy storage device to reach a maximum state of charge is an electric machine having a power supply that is shorter than the second energy storage device, the first energy storage device being configured to directly supply power to the first energy consumption unit, the first energy storage device and the second energy storage device being configured such that when a voltage of the first energy storage device falls below a voltage threshold, the second energy storage device automatically provides a backup power source to supply power to the first energy storage device, and the electric machine comprising a circuit element disposed between the first energy storage device and the second energy storage device, the circuit element being configured to pass current in only one direction from the second energy storage device to the first energy consumption unit. [2] The electric machine of [1], wherein the first energy storage device comprises one or more supercapacitors and the second energy storage device comprises one or more batteries. [3] The electric machine described in [1], wherein the circuit element is a diode, and when the second energy storage device provides a backup power source for the first energy consumption unit, the diode only passes current flowing from the second energy storage device through the diode to the first energy consumption unit. [4] The electric machine described in [1] or [2], wherein the circuit element is an electronically controlled switch configured to flow current in only one direction from the second energy storage device to the first energy consumption unit when the second energy storage device provides a backup power source for the first energy consumption unit. [5] An electric machine as described in any one of the preceding claims, wherein a DC / DC converter is arranged between the first energy storage device and the second energy storage device, the DC / DC being capable of flowing current from at least the first energy storage device to the second energy storage device. [6] The electric machine described in [5], wherein the DC / DC converter is unidirectional. [7] The electric machine described in [5], wherein the DC / DC converter is bidirectional. [8] An electric machine as claimed in any one of the preceding claims, wherein the electric machine is an electric vehicle, the first energy consumer is a propulsion system in the electric vehicle, and the second consumer is at least one auxiliary system in the vehicle. [9] An electric machine as described in any one of [1] to [7], wherein the electric machine is an electric tool, the first consumer unit is composed of at least one high-power subsystem in the tool, and the second consumer unit is composed of at least one low-power auxiliary subsystem in the tool.

[10] The vehicle includes a controller configured to perform at least power management; The controller: determining a predetermined route for the vehicle to travel between a first charging point and a second charging point; determining a fully charged state at the first charging point when the first energy storage device is fully charged; determining a total energy required for the vehicle to travel from the first charging point to the second charging point; determining an excess energy based on the full state of charge and the total energy; operating the machine to use the surplus energy to charge the second energy storage device during at least a portion of the journey between the first charging point and the second charging point. 13. An electric machine according to any one of claims 1 to 8.

[11] The electric machine described in

[10] , wherein the vehicle is configured to perform loading and unloading operations between at least one of the first charging point or the second charging point, the loading and unloading operations being performed by an auxiliary subsystem in the vehicle powered by the second energy storage device.

[12] An electric machine as claimed in any one of the preceding claims, wherein the first energy storage device has a power that is at least five times, preferably at least ten times, that of the second energy storage device, and the second energy storage device has an energy capacity that is at least twice that of the first energy storage device.

[13] An electric machine according to any one of the preceding claims, wherein the first energy storage device is configured to be fully charged in less than 15 minutes, preferably less than 10 minutes, more preferably less than 5 minutes.

[14] An electric machine as claimed in any preceding claim, wherein the first energy storage device comprises at least one of a flywheel, a hydraulic energy storage device, or a compressed air energy storage device.

[15] A method of configuring an electric machine, comprising the steps of: The method includes providing a first energy consumer and a second energy consumer, the first energy consumer requiring a higher output energy source and the second energy consumer requiring a lower output energy source; and providing a first energy storage device and a second energy storage device, the first energy storage device being higher output relative to the second energy storage device, the first energy storage device being configured to supply power to the first energy consumer and the second energy storage device being configured to supply power to the second energy consumer, the first energy storage device being connectable to a charger for charging, and the first energy storage device being connected to a charger for charging. a first energy storage device configured to directly supply power to the first energy consumer; the first and second energy storage devices configured such that the second energy storage device automatically provides a backup power source to power the first energy storage device when a voltage of the first energy storage device falls below a voltage threshold; and the electric machine includes a circuit element disposed between the first energy storage device and the second energy storage device, the circuit element configured to pass current in only one direction from the second energy storage device to the first energy consumer.

Claims

1. An electric machine comprising a first energy consumer and a second energy consumer, the first energy consumer requires a higher power energy source and the second energy consumer requires a lower power energy source; the electric machine further comprises a first energy storage device and a second energy storage device, the first energy storage device being higher power relative to the second energy storage device, the first energy storage device being configured to supply power to the first energy consumer and the second energy storage device being configured to supply power to the second energy consumer; the first energy storage device is connectable to a charger for charging, the first energy storage device taking less time to reach a maximum state of charge than the second energy storage device, the first energy storage device is configured to directly supply power to the first energy consumption unit, eliminating the need for a converter in between, the first energy storage device and the second energy storage device are configured such that when a voltage of the first energy storage device falls below a voltage threshold, the second energy storage device automatically provides a backup power source to power the first energy consumption unit, and the electric machine comprises a circuit element disposed between the first energy storage device and the second energy storage device, the circuit element configured to pass current in only one direction from the second energy storage device to the first energy consumption unit as a backup system.

2. The electric machine of claim 1 , wherein the first energy storage device comprises one or more supercapacitors and the second energy storage device comprises one or more batteries.

3. 2. The electric machine of claim 1, wherein the circuit element is a diode, and the diode only passes current from the second energy storage device through the diode to the first energy consumer when the second energy storage device provides a backup power source for the first energy consumer.

4. 3. The electric machine of claim 1, wherein the circuit element is an electronically controlled switch configured to pass current in only one direction from the second energy storage device to the first energy consumer when the second energy storage device provides a backup power source for the first energy consumer.

5. 5. The electric machine of claim 1, further comprising a DC / DC converter disposed between the first energy storage device and the second energy storage device, the DC / DC converter being capable of passing current from at least the first energy storage device to the second energy storage device.

6. The electric machine of claim 5 , wherein the DC / DC converter is unidirectional.

7. The electric machine of claim 5 , wherein the DC / DC converter is bidirectional.

8. 8. The electric machine of claim 1 , wherein the electric machine is an electric vehicle, the first energy consumer is a propulsion system in the electric vehicle, and the second energy consumer comprises at least one auxiliary system in the electric vehicle.

9. 8. The electric machine of claim 1, wherein the electric machine is an electric tool, the first energy consumer being composed of at least one high-power subsystem in the electric tool, and the second energy consumer being composed of at least one low-power auxiliary subsystem in the electric tool.

10. An electric vehicle comprising: a controller configured to perform at least power management; The controller: determining a predetermined route for the electric vehicle to travel between a first charging point and a second charging point; determining a fully charged state at the first charging point when the first energy storage device is fully charged; determining a total energy required for the electric vehicle to travel from the first charging point to the second charging point; determining an excess energy based on the full state of charge and the total energy; 9. An electric machine as claimed in any one of claims 1 to 8, wherein the electric machine is operated to charge the second energy storage device using the surplus energy during at least a portion of a journey between the first charging point and the second charging point.

11. 11. The electric machine of claim 10, wherein the electric vehicle is configured to perform loading and unloading operations between at least one of the first charging point or the second charging point, the loading and unloading operations being performed by auxiliary subsystems in the electric vehicle powered by the second energy storage device.

12. 12. The electric machine of claim 1, wherein the first energy storage device has at least five times the power of the second energy storage device and the second energy storage device has at least two times the energy capacity of the first energy storage device.

13. The electric machine of claim 1 , wherein the first energy storage device is configured to be fully charged in less than 15 minutes.

14. The electric machine of claim 1 , wherein the first energy storage device comprises at least one of a flywheel, a hydraulic energy storage device, or a compressed air energy storage device.

15. 1. A method of configuring an electric machine, comprising the steps of: The method includes providing a first energy consumer and a second energy consumer, the first energy consumer requiring a higher output energy source and the second energy consumer requiring a lower output energy source, and providing a first energy storage device and a second energy storage device, the first energy storage device being higher output relative to the second energy storage device, the first energy storage device being configured to supply power to the first energy consumer and the second energy storage device being configured to supply power to the second energy consumer, the first energy storage device being connectable to a charger for charging, and a maximum charge required in the first energy storage device to reach a maximum state of charge. the first energy storage device is configured to directly supply power to the first energy consumer, eliminating the need for a converter in between; the first energy storage device and the second energy storage device are configured such that the second energy storage device automatically provides a backup power source to power the first energy consumer when a voltage of the first energy storage device falls below a voltage threshold; and the electric machine comprises a circuit element disposed between the first energy storage device and the second energy storage device, the circuit element configured to pass current in only one direction from the second energy storage device to the first energy consumer as a backup system.

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