Modular cascaded energy system with cooling and interchangeable energy source capabilities

Abstract

Exemplary embodiments of systems, devices, and methods for cooling a modular energy system are provided herein. The embodiments can utilize an enclosure surrounding the modular energy system to pump a coolant through components of the modules of the modular energy system in close proximity. The embodiments can provide a sequence for pumping the coolant so that the coolant first cools components of the electric vehicle having the lowest desired operating temperatures, followed by components having relatively higher desired operating temperatures. Exemplary embodiments of systems, devices, and methods for modular energy systems with removable and replaceable energy sources are also provided herein.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 009,996, filed April 14, 2020, and U.S. Provisional Application No. 63 / 086,003, filed September 28, 2020, both of which are incorporated herein by reference in their entirety and for all purposes. (Technical field)

[0002] The subject matter described herein generally relates to systems, devices, and methods for providing cooling for modular cascaded energy systems and providing the ability to remove and replace energy sources. [Background technology]

[0003] Energy systems with multiple energy sources or sinks are common in many industries. One example is the automotive industry. Current automotive technology, as developed over the past century, is characterized by the interplay of motors, mechanical elements, and electronics, among other things. These are key components that influence vehicle performance and the driver experience. Motors can be combustion or electric, and in almost all cases, rotational energy from the motor is delivered through a highly sophisticated set of mechanical elements, such as clutches, transmissions, differentials, drive shafts, torque tubes, and couplers. These components largely control torque conversion and power distribution to the wheels, defining the vehicle's performance and drivability.

[0004] Electric vehicles (EVs) include various electrical systems associated with the drivetrain, including, among other things, a battery pack, a charger, and motor control. High-voltage battery packs are typically organized into a series chain of low-voltage battery modules. Each such module further includes a series-connected set of individual cells and a simple built-in battery management system (BMS) for regulating basic battery-related characteristics such as state of charge and voltage. Electronics with more sophisticated capabilities or some form of high-performance interconnectivity are absent. As a result, any monitoring or control functions are handled by separate systems, which, even if present elsewhere in the car, lack the ability to monitor individual battery health, state of charge, temperature, and other performance-affecting metrics. Any form of meaningful regulation of power draw per individual battery is also absent. Some of the major consequences are: (1) the weakest cell limits the overall performance of the entire battery pack; (2) failure of any cell or module leads to the need to replace the entire pack; (3) battery reliability and safety are significantly reduced; (4) battery life is limited; (5) thermal management is difficult; (6) the battery pack always operates below its maximum capacity; and (7) the sudden influx of regenerated braking-derived power cannot be easily stored in the battery and requires dissipation through a dump resistor.

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

[0006] Conventional control involves a DC-DC conversion stage to adjust the battery pack voltage level to the bus voltage of the EV's electrical system. The electric motor is then driven by a simple two-stage multi-phase converter, which provides the required AC signal to the motor. Each motor is traditionally controlled by a separate controller, driving the motor in a three-phase design. A dual-motor EV would require two controllers, while an EV using four in-wheel motors would require four individual controllers. Conventional controller designs also lack the ability to drive next-generation motors, such as switched reluctance motors (SRMs), which are characterized by a larger number of pole pieces. Adaptation would require a higher-order phase design, making the system more complex and ultimately unable to cope with electrical noise and drive performance, such as high torque ripple and acoustic noise.

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

[0008] Exemplary embodiments of systems, devices, and methods for cooling a modular energy system are provided herein. The embodiments can utilize an enclosure that encloses the modular energy system to pump a coolant through modules in the modular energy system in a manner that passes the coolant in close proximity to the components. The embodiments can provide a sequence for pumping the coolant so that the coolant first cools components of the electric vehicle having the lowest desired operating temperatures, followed by components having relatively higher desired operating temperatures.

[0009] Also provided herein are exemplary embodiments of systems, devices, and methods for a modular energy system with removable and replaceable energy sources. The systems can be configured in a variety of different electrical configurations and positioned within an electric vehicle in a manner that allows for rapid removal of energy sources having a relatively low state of charge and replacement of those energy sources with different energy sources having a relatively higher state of charge. The energy sources can be releasably latched in place within the electric vehicle such that each energy source is removable from electrical connection with its associated converter electronics.

[0010] Other systems, devices, methods, features, and advantages of the subject matter described herein will be, or become, apparent to one with skill in the art upon examination of the following figures and detailed description. All such additional systems, methods, features, and advantages are intended to be included within this description, be within the scope of the subject matter described herein, and be protected by the accompanying claims. Features of the exemplary embodiments should not be construed as limiting the appended claims in any way absent express recitation of those features in the claims. The present invention provides, for example, the following. (Item 1) 1. A modular energy system controllable to supply electrical power to a load, the system comprising: a plurality of modules connected together to output an AC voltage signal, the AC voltage signal comprising a superposition of a first output voltage from each module, each module comprising an energy source and converter electronics connected to the energy source, the converter electronics configured to generate the first output voltage from the energy source; an enclosure for the plurality of modules; Equipped with The enclosure is configured to pass a coolant through it to cool the plurality of modules. (Item 2) Item 10. The system of item 1, wherein the enclosure includes a conduit section configured to pass the coolant. (Item 3) Item 3. The system of item 2, wherein the enclosure comprises a channel having a shape corresponding to the shape of the conduit segment, and the conduit segment is positioned within the channel. (Item 4) Item 4. The system of item 3, wherein the conduit section is an interference fit within the channel. (Item 5) Item 3. The system of item 2, wherein a first module of the plurality of modules has the converter electronics mounted on a substrate, the substrate being positioned between the conduit section and the converter electronics of the first module. (Item 6) Item 6. The system of item 5, wherein the substrate and converter electronics are positioned between the energy source of the first module and the conduit section. (Item 7) Item 6. The system of item 5, further comprising a heat sink positioned between the conduit section and the substrate. (Item 8) Item 8. The system of item 7, further comprising an interface layer positioned between the conduit section and the heat sink. (Item 9) Item 9. The system of item 8, wherein the interface layer is deformable. (Item 10) Item 9. The system of item 8, wherein the conduit section contacts the interface layer, the interface layer contacts the heat sink, and the heat sink contacts the substrate. (Item 11) Item 6. The system of item 5, wherein each of the plurality of modules has the converter electronics mounted on a substrate, the substrate being positioned between the conduit section and the converter electronics of each module. (Item 12) 10. The system of any of items 2-9, wherein the enclosure comprises a first base section, a second section opposite the base section, and a sidewall section. (Item 13) Item 13. The system of item 12, wherein the conduit section is within at least one of the first base section, the second section, and the sidewall section. (Item 14) Item 14. The system of item 13, wherein the second section is a lid of the enclosure and the conduit section is within the lid. (Item 15) 1. A method for cooling a modular energy system of an electric vehicle, the method comprising: pumping a coolant through a cooling device in proximity to the modular energy system such that the coolant cools modules of the modular energy system; then pumping the coolant adjacent to a motor of the EV to cool the motor; then pumping the coolant through a heat exchanger to cool the coolant; A method comprising: (Item 16) Pumping coolant through the cooling device comprises: pumping a coolant proximate to at least one battery of a module of the modular energy system to cool the at least one battery; then pumping a coolant adjacent to the electronics of the module to cool the electronics; Item 16. The method according to item 15, comprising: (Item 17) Item 16. The method of item 15, wherein pumping coolant through the cooling device comprises pumping coolant through a section of an enclosure of the modular energy system. (Item 18) Item 18. The method of item 17, wherein the section is at least one of a base section, a second section opposite the base section, and a sidewall section. (Item 19) Item 16. The method of item 15, wherein pumping coolant through the cooling device includes pumping coolant through a base section of an enclosure of the modular energy system and then through a second section of the enclosure opposite the base section. (Item 20) 20. The method of claim 19, wherein a battery of a module of the modular energy system is located adjacent to the base section and electronics of the module of the modular energy system is located adjacent to the second section. (Item 21) Item 18. The method of item 17, wherein pumping coolant through the cooling device includes pumping coolant through only one of the base section, the second section, and the sidewall section. (Item 22) 1. A modular energy system controllable to power a motor of an electric vehicle, the system comprising at least three arrays, each array comprising a plurality of modules connected together to output an AC voltage signal, the AC voltage signal comprising a superposition of first output voltages from each module; each module comprising an energy source and converter electronics configured to generate a first output voltage from the energy source; The AC voltage signals output by the three arrays provide three-phase power to the motor; The system wherein the energy source is releasably connectable to the converter electronics. (Item 23) 23. The system of claim 22, further comprising a latching mechanism configured to releasably connect the energy source to the converter electronics. (Item 24) 24. The system of claim 23, wherein each module includes a housing for holding the converter electronics. (Item 25) 25. The system of claim 24, wherein the housing is coupled to guide rails for the energy source. (Item 26) 26. The system of claim 25, wherein the energy source is slidable along the guide rail. (Item 27) 27. The system of any of items 22-26, wherein the energy source has a width, a length, and a height, and the length is at least twice the width. (Item 28) Item 28. The system of item 27, wherein the length is at least three times the width. (Item 29) Item 28. The system of item 27, wherein the length is at least four times the width. (Item 30) Item 24. The system of item 23, wherein the latching mechanism comprises a power connector for connecting the energy source to the converter electronics. (Item 31) The system of any of items 22-30, wherein the system includes at least one interconnection module having an energy source and a converter, the converter of the interconnection module being coupled to at least two of the arrays. (Item 32) Item 32. The system of item 31, wherein the interconnection module comprises a housing that holds the converter of the interconnection module, the housing comprising a control port, at least two connectors for coupling the converter to at least two of the arrays, and at least two connectors for coupling the energy source or the converter of the interconnection module to at least one auxiliary load. (Item 33) 33. The system of any of items 24-32, wherein the energy source is a battery module. (Item 34) Item 34. The system of item 33, wherein the housing of each module includes a connector for connecting the battery management system of the battery module to a local control device housed within the housing. (Item 35) 35. The system of any of items 22-34, comprising a control system for controlling the converter of the module. (Item 36) Item 36. The system of item 35, wherein the control system is configured to control intra-phase equilibrium within each array. (Item 37) Item 37. The system of item 36, wherein the control system is configured to control phase balance across the array. (Item 38) An electric vehicle, the electric vehicle comprising: an electric motor; a modular energy system configured in accordance with any of items 22-37 to provide power for the electric motor; At least one access panel and Equipped with the at least one access panel is configured to move between a first position covering an energy source of the modular energy system and a second position exposing the energy source for removal, the electric vehicle. (Item 39) Item 39. The electric vehicle of item 38, wherein the at least one access panel is a door configured to pivot. (Item 40) 1. A method of managing power for an electric vehicle including a modular energy system having at least three arrays, each array including a plurality of modules connected together in a cascaded manner to generate an AC voltage signal for a motor of the electric vehicle, each module including a battery module and converter electronics; The method comprises: removing a first battery module from a first location within the electric vehicle; inserting a second battery module into the first location within the electric vehicle; Including, The method, wherein the second battery module has a relatively higher state of charge than the first battery module. (Item 41) Item 41. The method of item 40, wherein removing the first battery module includes unlocking the first battery module from a locked state within the electric vehicle. (Item 42) Item 42. The method of item 41, further comprising locking the second battery module in the first position. (Item 43) 43. The method of any of items 40-42, further comprising, prior to removing the first battery module, moving an access panel of the electric vehicle from a closed position covering the first battery module to an open position exposing the first battery module. (Item 44) Item 44. The method of item 43, wherein the access panel is located under the passenger door. (Item 45) 45. The method of any of items 40-44, further comprising removing all battery modules from the electric vehicle and inserting different battery modules having a relatively higher state of charge than the removed battery modules. (Item 46) 46. ​​The method of any of items 40-45, wherein removing the first battery module from the first location within the electric vehicle includes removing the first battery module from electrical contact with first converter electronics associated with the first battery module. (Item 47) 47. The method of claim 46, wherein inserting the second battery module into the first location in the electric vehicle includes inserting the second battery module into electrical contact with the first converter electronics. (Item 48) 48. The method of any of items 40-47, wherein removing the first battery module from the first position in the electric vehicle includes sliding the first battery module along guide rails. (Item 49) 48. The method of any of items 40-47, wherein inserting the second battery module into the first position in the electric vehicle includes sliding the second battery module along guide rails. (Item 50) 50. The method of any of items 40-49, wherein the modular energy system is configured according to any of items 22-37. [Brief explanation of the drawings]

[0011] Details of the subject matter described herein, both as to its structure and operation, may be apparent from consideration of the accompanying drawings, in which like reference numerals refer to like parts. The components within the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the subject matter. Moreover, all illustrations are intended to convey the concept, in which relative size, shape, and other detailed attributes may be depicted diagrammatically, rather than literally or precisely.

[0012] [Figure 1-1] 1A-1C are block diagrams depicting exemplary embodiments of modular energy systems. [Figure 1-2] 1A-1C are block diagrams depicting exemplary embodiments of modular energy systems.

[0013] [Figure 1-3] 1D-1E are block diagrams depicting exemplary embodiments of control devices for energy systems.

[0014] [Figure 1-4] 1F-1G are block diagrams depicting exemplary embodiments of a modular energy system coupled with a load and a charging source.

[0015] [Figure 2A] 2A-2B are block diagrams depicting exemplary embodiments of modules and control systems within an energy system. [Figure 2B] 2A-2B are block diagrams depicting exemplary embodiments of modules and control systems within an energy system.

[0016] [Figure 2C] FIG. 2C is a block diagram depicting an exemplary embodiment of the physical configuration of the modules.

[0017] [Figure 2D]FIG. 2D is a block diagram depicting an exemplary embodiment of the physical configuration of a modular energy system.

[0018] [Figure 3-1] 3A-3C are block diagrams depicting exemplary embodiments of modules having various electrical configurations. [Figure 3-2] 3A-3C are block diagrams depicting exemplary embodiments of modules having various electrical configurations.

[0019] [Figure 4] 4A-4F are schematic diagrams depicting exemplary embodiments of energy sources.

[0020] [Figure 5] 5A-5C are schematic diagrams depicting exemplary embodiments of energy buffers.

[0021] [Figure 6-1] 6A-6C are schematic diagrams depicting exemplary embodiments of converters. [Figure 6-2] 6A-6C are schematic diagrams depicting exemplary embodiments of converters.

[0022] [Figure 7-1] 7A-7E are block diagrams depicting exemplary embodiments of modular energy systems having various topologies. [Figure 7-2] 7A-7E are block diagrams depicting exemplary embodiments of modular energy systems having various topologies.

[0023] [Figure 8A] FIG. 8A is a plot depicting an example output voltage of the module.

[0024] [Figure 8B] FIG. 8B is a plot depicting an example multi-level output voltage of an array of modules.

[0025] [Figure 8C] FIG. 8C is a plot depicting exemplary reference and carrier signals that can be used in a pulse width modulation control technique.

[0026] [Figure 8D] FIG. 8D is a plot depicting exemplary reference and carrier signals that can be used in a pulse width modulation control technique.

[0027] [Figure 8E] FIG. 8E is a plot depicting an exemplary switch signal generated according to a pulse width modulation control technique.

[0028] [Figure 8F] FIG. 8F is a plot depicting an exemplary multi-level output voltage generated by superposition of output voltages from an array of modules under pulse width modulation control techniques.

[0029] [Figure 9] 9A-9B are block diagrams depicting exemplary embodiments of a controller for a modular energy system.

[0030] [Figure 10A] FIG. 10A is a block diagram depicting an exemplary embodiment of a multi-phase modular energy system having interconnected modules.

[0031] [Figure 10B] FIG. 10B is a schematic diagram depicting an exemplary embodiment of an interconnection module in the multi-phase embodiment of FIG. 10A.

[0032] [Figure 10C] FIG. 10C is a block diagram depicting an exemplary embodiment of a modular energy system having two subsystems connected together by an interconnection module.

[0033] [Figure 10D] FIG. 10D is a block diagram depicting an exemplary embodiment of a three-phase modular energy system having interconnected modules supplying auxiliary loads.

[0034] [Figure 10E] FIG. 10E is a schematic diagram depicting an exemplary embodiment of an interconnection module in the multi-phase embodiment of FIG. 10D.

[0035] [Figure 10F] FIG. 10F is a block diagram depicting an exemplary embodiment of a three-phase modular energy system having interconnected modules supplying auxiliary loads.

[0036] [Figure 11A] FIG. 11A is a block diagram depicting an exemplary embodiment of a process flow for cooling components of an electric vehicle.

[0037] [Figure 11B] FIG. 11B is a perspective view depicting an exemplary embodiment of an enclosure configured for cooling a modular energy system.

[0038] [Figure 11C] FIG. 11C is a block diagram depicting another exemplary embodiment of a process flow for cooling components of an electric vehicle.

[0039] [Figure 11D] FIG. 11D is a perspective view depicting another exemplary embodiment of an enclosure configured for cooling a modular energy system.

[0040] [Figure 11E] FIG. 11E is a perspective view depicting an exemplary embodiment of modular component installation relative to the upper enclosure.

[0041] [Figure 11F] FIG. 11F is a cross-sectional view depicting an exemplary embodiment of a module adjacent to a cooling device.

[0042] [Figure 12] 12A-12B are side views depicting an exemplary embodiment of an electric vehicle configured to operate with a replaceable battery module.

[0043] [Figure 13A] FIG. 13A is a schematic diagram depicting an exemplary embodiment of a modular energy system having replaceable battery modules in an electric vehicle.

[0044] [Figure 13B] FIG. 13B is a block diagram depicting an exemplary embodiment of an electrical layout for the modular energy system of FIG. 13A.

[0045] [Figure 14-1] 14A, 14D, 14E, and 14F are perspective views depicting an exemplary embodiment of a converter module with a replaceable battery module in various states of engagement and disengagement. [Figure 14-2] 14B-14C are end views depicting an exemplary embodiment of a housing for modular electronics.

[0046] [Figure 14-3] 14A, 14D, 14E, and 14F are perspective views depicting an exemplary embodiment of a converter module with a replaceable battery module in various states of engagement and disengagement. [Figure 14-4] 14A, 14D, 14E, and 14F are perspective views depicting an exemplary embodiment of a converter module with a replaceable battery module in various states of engagement and disengagement. DETAILED DESCRIPTION OF THE INVENTION

[0047] Before the present subject matter is described in detail, it is to be understood that this disclosure is not limited to particular embodiments described, as such may, of course, vary. It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, as the scope of the present disclosure will be limited only by the appended claims.

[0048] Before describing exemplary embodiments relating to the cooling system and exchangeable energy sources, it is useful to first describe these underlying modular energy systems in more detail. With reference to Figures 1A-10F, the following sections describe various application modular energy system embodiments in which modular energy system embodiments may be implemented, control system or device embodiments for the modular energy system, configuration of modular energy system embodiments relative to charging sources and loads, embodiments of individual modules, embodiments of topologies for arranging modules in the system, embodiments of control methodologies, embodiments of balanced operating characteristics of modules in the system, and embodiments of the use of interconnected modules. (Example of use)

[0049] Stationary applications are those in which a modular energy system resides at a fixed location during use but may be capable of being transported to an alternative location when not in use. A module-based energy system provides electrical energy for consumption by one or more other entities while residing at a static location, or stores or buffers energy for later consumption. Examples of stationary applications in which embodiments disclosed herein may be used include, but are not limited to, energy systems for use by or within one or more residential structures or locations, energy systems for use by or within one or more industrial structures or locations, energy systems for use by or within one or more commercial structures or locations, energy systems for use by or within one or more government structures or locations (including both military and non-military uses), energy systems for charging mobile applications described below (e.g., charging sources or charging stations), and systems that convert solar power, wind power, geothermal energy, fossil fuels, or nuclear reactions into electricity for storage. Stationary applications often supply loads such as grids and microgrids, motors, and data centers. Stationary energy systems can be used in either a storage or non-storage role.

[0050] Mobile applications, sometimes referred to as traction applications, generally involve a modular energy system located on or within an entity that stores and provides electrical energy for conversion into motive power by a motor to move or assist in moving the entity. Examples of mobile entities with which the embodiments disclosed herein may be used include, but are not limited to, electric and / or hybrid entities that travel over land or underground, over or under the sea, above land or sea without contact therewith (e.g., flying or hovering in the air), or through space. Examples of mobile entities with which the embodiments disclosed herein may be used include, but are not limited to, cars, trains, trams, ships, watercraft, aircraft, and spacecraft. Examples of mobile vehicles with which the embodiments disclosed herein may be used include, but are not limited to, those with only one wheel or track, those with only two wheels or tracks, those with only three wheels or tracks, those with only four wheels or tracks, and those with five or more wheels or tracks. Examples of mobile entities with which the embodiments disclosed herein may be used include, but are not limited to, cars, buses, trucks, motorcycles, scooters, industrial vehicles, mining vehicles, air vehicles (e.g., airplanes, helicopters, drones, etc.), watercraft (e.g., commercial transport vessels, ships, yachts, boats, or other water vehicles), submarines, locomotives or rail-based vehicles (e.g., trains, etc.), military vehicles, spacecraft, and satellites.

[0051] In describing embodiments herein, reference may be made to a particular stationary application (e.g., a grid, a microgrid, a data center, a cloud computing environment) or a mobile application (e.g., an electric vehicle). Such references are made for ease of explanation and do not imply that a particular embodiment is limited for use only in that particular mobile or stationary application. Embodiments of a system for providing power to a motor can be used in both mobile and stationary applications. While certain configurations may be more suitable for some applications than others, all exemplary embodiments disclosed herein are capable of use in both mobile and stationary applications unless otherwise stated. (Example of a module-based energy system)

[0052] FIG. 1A is a block diagram depicting an exemplary embodiment of a module-based energy system 100. Here, system 100 includes a control system 102 communicatively coupled to N converter source modules 108-1 through 108-N via communication paths or links 106-1 through 106-N, respectively. The modules 108 are configured to store energy and output energy to a load 101 (or other modules 108) as needed. In these embodiments, any number of two or more modules 108 can be used (e.g., N is greater than or equal to two). The modules 108 can be interconnected in various manners, as will be described in further detail with respect to FIGS. 7A-7E. For ease of illustration, in FIGS. 1A-1C, the modules 108 are shown connected in series or as a one-dimensional array, with the Nth module coupled to the load 101.

[0053] System 100 is configured to supply power to load 101. Load 101 can be any type of load, such as a motor or a grid. System 100 is also configured to store power received from a charging source. FIG. 1F is a block diagram depicting an exemplary embodiment of system 100 with a power input interface 151 for receiving power from charging source 150 and a power output interface for outputting power to load 101. In this embodiment, system 100 can receive and store power via interface 151 while simultaneously outputting power via interface 152. FIG. 1G is a block diagram depicting another exemplary embodiment of system 100 with a switchable interface 154. In this embodiment, system 100 can select, or be instructed to select, between receiving power from charging source 150 and outputting power to load 101. The system 100 can be configured to supply multiple loads 101, including both primary and auxiliary loads, and / or receive power from multiple charging sources 150 (e.g., a utility grid and local renewable energy sources (e.g., solar)).

[0054] 1B depicts another exemplary embodiment of system 100. Here, control system 102 is implemented as a master control device (MCD) 112 that is communicatively coupled to N different local control devices (LCDs) 114-1-114-N via communication paths or links 115-1-115-N, respectively. Each LCD 114-1-114-N is communicatively coupled to one module 108-1-108-N via communication paths or links 116-1-116-N, respectively, such that a 1:1 relationship exists between the LCD 114 and the module 108.

[0055] 1C depicts another exemplary embodiment of system 100. Here, MCD 112 is communicatively coupled to M different LCDs 114-1 to 114-M via communication paths or links 115-1 to 115-M, respectively. Each LCD 114 is coupled to and can control two or more modules 108. In the example shown, here, each LCD 114 is communicatively coupled to two modules 108, such that MCDs 114-1 to 114-M are coupled to 2M modules 108-1 to 108-2M via communication paths or links 116-1 to 116-2M, respectively.

[0056] The control system 102 can be configured as a single device for the entire system 100 (e.g., FIG. 1A), or can be distributed or implemented across multiple devices (e.g., FIGS. 1B-1C). In some embodiments, the control system 102 can be distributed among the LCDs 114 associated with the modules 108, such that any MCDs 112 are not required and may be omitted from the system 100.

[0057] Control system 102 can be configured to perform control using software (instructions stored in memory executable by processing circuitry), hardware, or a combination thereof. Each of the one or more devices of control system 102 can include processing circuitry 120 and memory 122, as shown here. Exemplary implementations of processing circuitry and memory are described further below.

[0058] The control system 102 may have a communication interface for communicating with devices 104 external to the system 100 via communication links or paths 105. For example, the control system 102 (e.g., the MCD 112) may output data or information about the system 100 to another control device 104 (e.g., a vehicle's electronic control unit (ECU) or motor control unit (MCU) in a mobile application, a grid controller in a stationary application, etc.).

[0059] Each of the communication paths or links 105, 106, 115, 116, and 118 (FIG. 2B) can be a wired (e.g., electrical, optical) or wireless communication path that communicates data or information bidirectionally, in parallel or serial fashion. Data can be communicated in a standardized (e.g., IEEE, ANSI) or custom (e.g., proprietary) format. In automotive applications, the communication path 115 can be configured to communicate according to the FlexRay or CAN protocol. The communication paths 106, 115, 116, and 118 also provide wired power and can directly supply operating power for the system 102 from one or more modules 108. For example, operating power for each LCD 114 can be supplied solely by the one or more modules 108 to which the LCD 114 is connected, while operating power for the MCD 112 can be indirectly supplied from one or more of the modules 108 (e.g., through the vehicle's power network, etc.).

[0060] The control system 102 is configured to control one or more modules 108 based on status information received from the same or different one or more of the modules 108. The control can also be based on one or more other factors, such as the requirements of the load 101. Controllable aspects include, but are not limited to, one or more of the voltage, current, phase, and / or output power of each module 108.

[0061] Status information for all modules 108 in system 100 can be communicated to control system 102, which can independently control all modules 108-1...108-N. Other variations are possible. For example, a particular module 108 (or a subset of modules 108) can be controlled based on status information for that particular module 108 (or subset), based on status information for a different module 108 that is not the particular module 108 (or subset), based on status information for all modules 108 other than the particular module 108 (or subset), based on status information for the particular module 108 (or subset) and status information for at least one other module 108 that is not the particular module 108 (or subset), or based on status information for all modules 108 in system 100.

[0062] The status information can be information about one or more aspects, characteristics, or parameters of each module 108. Types of status information include, but are not limited to, the following aspects of a module 108 or one or more of its components (e.g., energy source, energy buffer, converter, monitor circuitry): the state of charge (SOC) of one or more energy sources of the module (e.g., the level of charge of an energy source relative to its capacity, such as a fraction or percent), the state of health (SOH) of one or more energy sources of the module (e.g., a figure of merit of the condition of an energy source compared to its ideal condition), the temperature of one or more energy sources or other components of the module, the capacity of one or more energy sources of the module, the voltage of one or more energy sources and / or other components of the module, the current of one or more energy sources and / or other components of the module, and / or the presence or absence of a fault in any one or more of the components of the module.

[0063] The LCD 114 can be configured to receive status information from each module 108 or determine status information from monitored signals or data received from or within each module 108 and communicate that information to the MCD 112. In some embodiments, each LCD 114 can communicate raw collected data to the MCD 112, which then algorithmically determines status information based on the raw data. The MCD 112 can then use the module 108 status information to make control decisions, as appropriate. Decisions can take the form of instructions, commands, or other information (such as modulation indexes described herein) that can be utilized by the LCD 114 to either maintain or adjust the operation of each module 108.

[0064] For example, the MCD 112 may receive status information, evaluate the information, and determine differences between at least one module 108 (e.g., its components) and at least one or more other modules 108 (e.g., its comparable components). For example, the MCD 112 may determine that a particular module 108 is operating with one of the following conditions compared to one or more other modules 108: a relatively low or high SOC, a relatively low or high SOH, a relatively low or high capacity, a relatively low or high voltage, a relatively low or high current, a relatively low or high temperature, or the presence or absence of a fault. In such an example, the MCD 112 may output control information to reduce or increase (depending on the condition) a relevant aspect (e.g., output voltage, current, power, temperature) of that particular module 108. In this manner, the utilization of an outlier module 108 (e.g., operating with a relatively low SOC or high temperature) can be reduced to cause the relevant parameter (e.g., SOC or temperature) of that module 108 to converge toward that of one or more other modules 108.

[0065] The decision whether to adjust the operation of a particular module 108 can be made by comparing the status information with predetermined thresholds, limits, or conditions, not necessarily by comparison with the status of other modules 108. The predetermined thresholds, limits, or conditions can be static thresholds, limits, or conditions, such as those set by a manufacturer, that do not change during use. The predetermined thresholds, limits, or conditions can be dynamic thresholds, limits, or conditions that are allowed to change or change during use. For example, the MCD 112 can adjust the operation of a module 108 if the status information for that module 108 indicates that it is violating (e.g., above or below) a predetermined threshold or limit or is operating outside a predetermined range of acceptable operating conditions. Similarly, the MCD 112 can adjust the operation of a module 108 if the status information for that module 108 indicates the presence of an actual or potential fault (e.g., an alarm or warning), or the absence or removal of an actual or potential fault. Examples of faults include, but are not limited to, actual failure of a component, potential failure of a component, short circuits or other excessive current conditions, open circuits, excessive voltage conditions, poor reception of communications, reception of corrupted data, and the like. Depending on the type and severity of the fault, the amount of utilization of the faulty module can be reduced to avoid damaging the module, or utilization of the module can be stopped entirely.

[0066] The MCD 112 can control the modules 108 in the system 100 to achieve or converge toward a desired target. The target can be, for example, that the performance of all modules 108 is at the same or similar level relative to one another, or within a predetermined threshold, limit, or condition. This process can also be referred to as seeking to achieve balance or equilibrium in the operation or operating characteristics of the modules 108. The term “balance,” as used herein, does not require absolute equality between the modules 108 or their components, but rather is used broadly to convey that the operation of the system 100 can be used to actively reduce inequalities in the performance of the modules 108 that would otherwise exist.

[0067] The MCD 112 can communicate control information to the LCD 114 for purposes of controlling the module 108 associated with the LCD 114. The control information can be, for example, a modulation index and reference signal as described herein, a modulated reference signal, or others. Each LCD 114 can use (e.g., receive and process) the control information to generate switch signals that control the operation of one or more components (e.g., converters) within the associated module 108. In some embodiments, the MCD 112 generates the switch signals directly and outputs them to the LCD 114, which relays the switch signals to the intended module components.

[0068] All or a portion of the control system 102 can be combined with a system external control device 104 that controls one or more other aspects of the mobile or stationary application. When integrated within this shared or common control device (or subsystem), control of the system 100 can be implemented in any desired manner, such as by one or more software applications executed by processing circuitry of the shared device, by hardware in the shared device, or a combination thereof. Non-exhaustive examples of external control device 104 include an on-board ECU or MCU having control capabilities for one or more other on-board functions (e.g., motor control, driver interface control, traction control, etc.), a grid or microgrid controller responsible for one or more other power management functions (e.g., load interfacing, load power requirement prediction, transmission and switching, interfacing with charging sources (e.g., diesel, solar, wind), charging source power prediction, backup source monitoring, asset dispatch, etc.), and a data center control subsystem (e.g., environmental control, network control, backup control, etc.).

[0069] 1D and 1E are block diagrams depicting an example embodiment of a shared or common control device (or system) 132 in which control system 102 may be implemented. In FIG. 1D , common control device 132 includes master control device 112 and external control device 104. Master control device 112 includes interface 141 for communication with LCD 114 via path 115 and interface 142 for communication with external control device 104 via internal communication bus 136. External control device 104 includes interface 143 for communication with master control device 112 via bus 136 and interface 144 for communication with other entities in the overall application (e.g., vehicle or grid components) via communication path 136. In some embodiments, common control device 132 can be integrated as a common housing or package, with devices 112 and 104 implemented as discrete integrated circuit (IC) chips or packages contained therein.

[0070] In FIG. 1E, the external control device 104 acts as a common control device 132, with master control functionality implemented as a component 112 within the device 104. This component 112 can be or include software or other program instructions stored and / or hard-coded within the device 104's memory and executed by its processing circuitry. The component can also include dedicated hardware. The component can be a self-contained module or core, with one or more internal hardware and / or software interfaces (e.g., application program interfaces (APIs)) for communication with the external control device 104's operating software. The external control device 104 can manage communication with the LCD 114 via interface 141 and with other devices via interface 144. In various embodiments, the devices 104 / 132 can be integrated as a single IC chip, integrated into multiple IC chips within a single package, or integrated as multiple semiconductor packages within a common housing.

[0071] 1D and 1E, the master control functionality of the system 102 is shared within the common device 132; however, other divisions of shared control are also possible. For example, a portion of the master control functionality can be distributed between the common device 132 and the dedicated MCD 112. In another example, both the master control functionality and at least a portion of the local control functionality can be implemented within the common device 132 (e.g., the remaining local control functionality is implemented within the LCD 114). In some embodiments, the control system 102 is implemented entirely within the common device (or subsystem) 132. In some embodiments, the local control functionality is implemented within a device shared with another component of each module 108, such as a battery management system (BMS). (Example of a module with a cascaded energy system)

[0072] Module 108 can include one or more energy sources, a power electronics converter, and, optionally, an energy buffer. Figures 2A-2B are block diagrams depicting additional exemplary embodiments of system 100 with module 108 having a power converter 202, an energy buffer 204, and an energy source 206. Converter 202 can be a voltage converter or a current converter. While embodiments are described herein with reference to a voltage converter, embodiments are not limited thereto. Converter 202 can be configured to convert a direct current (DC) signal from energy source 204 to an alternating current (AC) signal and output it via power connection 110 (e.g., an inverter). Converter 202 can also receive an AC or DC signal via connection 110 and apply it to energy source 204 with either polarity in a continuous or pulsed form. Converter 202 can be or include an arrangement of switches (e.g., power transistors), such as a half-bridge or full-bridge (H-bridge). In some embodiments, the converter 202 includes only switches, and the converter (and the module as a whole) does not include a transformer.

[0073] Converter 202 can also (or alternatively) be configured to perform AC-to-DC conversion (e.g., a rectifier), DC-to-AC conversion, and / or AC-to-AC conversion (e.g., in combination with an AC-to-DC converter), such as for charging a DC energy source from an AC source. In some embodiments, such as for performing AC-to-AC conversion, converter 202 can include a transformer, either alone or in combination with one or more power semiconductors (e.g., switches, diodes, thyristors, and the like). In other embodiments, such as those where weight and cost are significant factors, converter 202 can be configured to perform the conversion using only power switches, power diodes, or other semiconductor devices and without a transformer.

[0074] The energy source 206 is preferably a robust energy storage device capable of outputting direct current and having an energy density suitable for energy storage applications for electrically powered devices. The fuel cell can be a single fuel cell, multiple fuel cells connected in series or parallel, or a fuel cell module. Two or more energy sources can be included within each module, where the two or more sources can include two batteries of the same or different types, two capacitors of the same or different types, two fuel cells of the same or different types, one or more batteries combined with one or more capacitors and / or fuel cells, and one or more capacitors combined with one or more fuel cells.

[0075] The energy source 206 can be an electrochemical battery, such as a single battery cell, or multiple battery cells connected together in a battery module or array, or any combination thereof. Figures 4A-4D are schematic diagrams depicting example embodiments of the energy source 206 configured as a single battery cell 402 (Figure 4A), a battery module with a series connection of multiple (e.g., four) cells 402 (Figure 4B), a battery module with a parallel connection of single cells 402 (Figure 4C), and a battery module with a parallel connection of tributaries each having multiple (e.g., two) cells 402 (Figure 4D). Examples of battery types are described elsewhere herein.

[0076] Energy source 206 can also be a high-energy density (HED) capacitor, such as an ultracapacitor or supercapacitor. HED capacitors can be configured as double-layer capacitors (electrostatic charge storage), pseudocapacitors (electrochemical charge storage), hybrid capacitors (electrostatic and electrochemical), or others, as opposed to typical solid-dielectric electrolytic capacitors. In addition to higher capacitance, HED capacitors can have energy densities 10 to 100 times (or higher) than those of electrolytic capacitors. For example, HED capacitors can have specific energies greater than 1.0 watt-hours per kilogram (Wh / kg) and capacitances greater than 10 to 100 farads (F). Similar to the battery described with respect to FIGS. 4A-4D , energy source 206 can be configured as a single HED capacitor or multiple HED capacitors connected together in an array (e.g., in series, parallel, or a combination thereof).

[0077] Energy source 206 can also be a fuel cell. Examples of fuel cells include proton exchange membrane fuel cells (PEMFCs), phosphoric acid fuel cells (PAFCs), solid acid fuel cells, alkaline fuel cells, high-temperature fuel cells, solid oxide fuel cells, molten electrolyte fuel cells, and others. Similar to the batteries described with respect to Figures 4A-4D, energy source 206 can be configured as a single fuel cell or multiple fuel cells connected together in an array (e.g., in series, parallel, or a combination thereof). The foregoing examples of batteries, capacitors, and fuel cells are not intended to form an exhaustive list, and one skilled in the art will recognize other variations that fall within the scope of the present subject matter.

[0078] The energy buffer 204 is connected to a DC line or link (e.g., +V DC , as described below). L and -V DC L) to help maintain stability in the DC link voltage. These fluctuations may be relatively low (e.g., kilohertz) or high (e.g., megahertz) frequency fluctuations or harmonics caused by switching or other transients in converter 202. These fluctuations may be absorbed by buffer 204 instead of being passed to source 206 or ports IO3 and IO4 of converter 202.

[0079] The power connection 110 is a connection for transporting energy or power to, from, and through the module 108. The module 108 can output energy from an energy source 206 to the power connection 110, where it can be transported to other modules or loads in the system. The module 108 can also receive energy from other modules 108 or from charging sources (DC chargers, single-phase chargers, multi-phase chargers). Signals can also be passed through the module 108 and bypass the energy source 206. The flow of energy or power into and out of the module 108 is performed by the converter 202 under the control of the LCD 114 (or another entity in the system 102).

[0080] In the embodiment of Figure 2A, the LCD 114 is implemented as a component separate from the module 108 (e.g., not in a shared module housing) and is capable of connecting to and communicating with the converter 202 via a communication path 116. In the embodiment of Figure 2B, the LCD 114 is included as a component of the module 108 and is capable of connecting to and communicating with the converter 202 via an internal communication path 118 (e.g., a shared bus or a discrete connection). The LCD 114 may also be capable of receiving signals from and transmitting signals to the energy buffer 204 and / or the energy source 206 via paths 116 or 118.

[0081] The module 108 may also include monitor circuitry 208 configured to monitor (e.g., collect, sense, measure, and / or determine) one or more aspects of the module 108 and / or its components, such as voltage, current, temperature, or other operating parameters, that compose status information (or that may be used to determine the status information, e.g., by the LCD 114). A primary function of the status information is to describe the state of one or more energy sources 206 of the module 108 and enable a decision regarding how much to utilize the energy source relative to other sources in the system 100, although status information describing the state of other components (e.g., voltage, temperature, and / or presence of a fault in the buffer 204, temperature and / or presence of a fault in the converter 202, presence of a fault anywhere in the module 108, etc.) may likewise be used in the utilization determination. The monitor circuitry 208 may include one or more sensors, shunts, dividers, fault detectors, coulomb counters, controllers, or other hardware and / or software configured to monitor such aspects. The monitor circuitry 208 can be separate from the various components 202, 204, and 206, or can be integrated with each component 202, 204, and 206 (as shown in FIGS. 2A-2B), or any combination thereof. In some embodiments, the monitor circuitry 208 can be part of or shared with a battery management system (BMS) for the battery energy source 204. Discrete circuitry is not required to monitor each type of status information, as more than one type of status information can be monitored using a single circuit or device or otherwise determined algorithmically without the need for additional circuitry.

[0082] The LCD 114 can receive status information (or raw data) about the module components via communication paths 116, 118. The LCD 114 can also transmit information to the module components via paths 116, 118. Paths 116 and 118 can include diagnostic, measurement, protection, and control signal lines. The transmitted information can be control signals for one or more module components. The control signals can be switch signals for the converter 202 and / or one or more signals requesting status information from the module components. For example, the LCD 114 can cause the status information to be transmitted via paths 116, 118 by directly requesting the status information or, in some cases, by applying a stimulus (e.g., a voltage) to generate the status information in combination with a switch signal that places the converter 202 in a particular state.

[0083] The physical configuration or layout of module 108 can take a variety of forms. In some embodiments, module 108 can include a common housing within which all module components, e.g., converter 202, buffer 204, and source 206, are housed along with other optional components, such as an integrated LCD 114. In other embodiments, the various components can be separated within discrete housings that are affixed together. FIG. 2C is a block diagram depicting an exemplary embodiment of module 108 having a first housing 220 that holds the module's energy source 206 and associated electronics, such as monitor circuitry 208 (not shown), a second housing 222 that holds module electronics, such as converter 202, energy buffer 204, and other associated electronics, such as monitor circuitry (not shown), and a third housing 224 that holds the LCD 114 (not shown) for module 108. Electrical connections between the various module components may pass through the housing 220 , 222 , 224 and may be exposed either on the housing exterior for connection to other devices such as other modules 108 or MCD 112 .

[0084] The modules 108 of the system 100 can be physically arranged relative to each other in various configurations, depending on the needs of the application and the number of loads. For example, in a stationary application where the system 100 provides power for a microgrid, the modules 108 can be installed in one or more racks or other frameworks. Such a configuration may also be suitable for larger mobile applications, such as marine vessels. Alternatively, the modules 108 can be affixed together and located in a common housing, referred to as a pack. The rack or pack may have its own dedicated cooling system shared across all modules. A pack configuration is useful for smaller mobile applications, such as electric vehicles. The system 100 can be implemented using one or more racks (e.g., for parallel supply to a microgrid), or one or more packs (e.g., to supply different motors in a vehicle), or a combination thereof. FIG. 2D is a block diagram depicting an example embodiment of the system 100 in which nine modules 108 are configured as a pack, electrically and physically coupled together within a common housing 230.

[0085] Examples of these and further configurations are described in International Application No. PCT / US20 / 25366, filed March 27, 2020, and entitled Module-Based Energy Systems Capable of Cascaded and Interconnected Configurations, and Methods Related Thereto, which is incorporated herein by reference in its entirety for all purposes.

[0086] 3A-3C are block diagrams depicting example embodiments of module 108 having various electrical configurations. These embodiments are described as having one LCD 114 / module 108, with the LCD 114 housed within an associated module, but may be otherwise configured as described herein. FIG. 3A depicts a first example configuration of module 108A within system 100. Module 108A includes an energy source 206, an energy buffer 204, and a converter 202A. Each component has a power connection port (e.g., terminal, connector), referred to herein as an IO port, into which and / or from which power may be input. Such ports may also be referred to as input or output ports, depending on the context.

[0087] The energy source 206 can be configured as any of the energy source types described herein (e.g., a battery, HED capacitor, fuel cell, or others, as described with respect to FIGS. 4A-4D ). Ports IO1 and IO2 of the energy source 206 can be connected to ports IO1 and IO2, respectively, of the energy buffer 204. The energy buffer 204 can be configured to buffer or filter high and low frequency energy waves arriving at the buffer 204 through the converter 202, which may otherwise degrade the performance of the module 108. The topology and components for the buffer 204 are selected to accommodate the maximum allowable amplitude of these high frequency voltage waves. Several (non-exhaustive) example embodiments of the energy buffer 204 are depicted in the schematic diagrams of FIGS. 5A-5C . In FIG. 5A , the buffer 204 is configured with an electrolytic and / or film capacitor C EB 5B, the buffer 204 is connected to two inductors L EB1 and L EB2 and two electrolytic and / or film capacitors C EB1 and C EB25C, the buffer 204 is formed by two inductors L EB1 and L EB2 and two electrolytic and / or film capacitors C EB1 and C EB2 and diode D EB and a quasi-Z-source network 720 formed by

[0088] Ports IO3 and IO4 of energy buffer 204 can be connected to ports IO1 and IO2, respectively, of converter 202A, which can be configured as any of the power converter types described herein. FIG. 6A is a schematic diagram depicting an example embodiment of converter 202A configured as a DC-AC converter that can receive DC voltages at ports IO1 and IO2 and switch pulses to generate at ports IO3 and IO4. Converter 202A can include multiple switches, here converter 202A includes four switches S3, S4, S5, and S6 arranged in a full-bridge configuration. Control system 102 or LCD 114 can control each switch independently via control input line 118-3 to each gate.

[0089] The switches can be any suitable switch type, such as power semiconductors such as metal-oxide-semiconductor field-effect transistors (MOSFETs) shown here, insulated-gate bipolar transistors (IGBTs), or gallium nitride (GaN) transistors. The semiconductor switches can operate at relatively high switching frequencies, thereby allowing converter 202 to be operated in pulse-width modulation (PWM) mode, if desired, and respond to control commands within relatively short time intervals. This can provide high tolerance and fast dynamic behavior of output voltage regulation in transient mode.

[0090] In this embodiment, the DC line voltage V DC Lcan be applied to the converter 202 between ports IO1 and IO2. Different combinations of switches S3, S4, S5, and S6 allow for V DC L By connecting the GND to ports IO3 and IO4, converter 202 can provide three different voltage outputs: +V DC L , 0, and -V DC L can be generated at ports IO3 and IO4. The switch signal provided to each switch controls whether the switch is turned on (closed) or off (open). L To obtain a -V DC voltage, switches S3 and S6 are turned on while S4 and S5 are turned off. L can be obtained by turning on switches S4 and S5 and turning off S3 and S6. The output voltages can be set to zero (including near zero) or a reference voltage by turning S4 and S6 off with S3 and S5 on, or by turning S3 and S5 off with S4 and S6 on. These voltages can be output from the module 108 via the power connection 110. Ports IO3 and IO4 of the converter 202 can be connected to (or from) module IO ports 1 and 2 of the power connection 110 to generate output voltages for use with output voltages from other modules 108.

[0091] Control or switch signals for the embodiments of converter 202 described herein can be generated in different ways depending on the control technique utilized by system 100 to generate the output voltage of converter 202. In some embodiments, the control technique is a PWM technique, such as space vector pulse-width modulation (SVPWM) or sinusoidal pulse-width modulation (SPWM), or variations thereof. FIG. 8A is a voltage versus time graph depicting an example of an output voltage waveform 802 of converter 202. For ease of explanation, embodiments herein will be described in the context of a PWM control technique, although embodiments are not limited thereto. Other classes of techniques can also be used. One alternative class is based on hysteresis, examples of which are described in International Publication Nos. WO 2018 / 231810 A1, WO 2018 / 232403 A1, and WO 2019 / 183553 A1 (incorporated herein by reference for all purposes).

[0092] Each module 108 can be configured with multiple energy sources 206 (e.g., two, three, four, or more). Each energy source 206 of a module 108 can be controllable (switchable) to supply power to the connection 110 (or receive power from a charging source) independently of the other sources 206 of the module. For example, all sources 206 can output power to (or be charged with) the connection 110 simultaneously, or only one (or a subset) of the sources 206 can supply power (or be charged) at any one time. In some embodiments, the sources 206 of a module can exchange energy between themselves, e.g., one source 206 can charge another source 206. Each of the sources 206 can be configured as any energy source described herein (e.g., a battery, a HED capacitor, a fuel cell). Each of the sources 206 can be of the same type (e.g., each can be a battery) or different types (e.g., a first source can be a battery and a second source can be a HED capacitor, or a first source can be a battery (e.g., NMC) having a first type and a second source can be a battery (e.g., LFP) having a second type).

[0093] 3B is a block diagram depicting an example embodiment of module 108B in a dual energy source configuration with a primary energy source 206A and a secondary energy source 206B. Ports IO1 and IO2 of primary source 202A can be connected to ports IO1 and IO2 of energy buffer 204. Module 108B includes converter 202B with an additional IO port. Ports IO3 and IO4 of buffer 204 can be connected to ports IO1 and IO2, respectively, of converter 202B. Ports IO1 and IO2 of secondary source 206B can be connected to ports IO5 and IO2, respectively, of converter 202B (and also connected to port IO4 of buffer 204).

[0094] In this exemplary embodiment of module 108B, primary energy source 202A, along with the other modules 108 of system 100, supplies the average power required by the load. Secondary source 202B can perform the function of an auxiliary energy source 202 by providing additional power at load power peaks, absorbing excess power, or otherwise.

[0095] As mentioned, both the primary source 206A and the secondary source 206B can be utilized simultaneously or at separate times depending on the switch state of the converter 202B. If simultaneously, the electrolytic and / or film capacitors (C ES ) can be placed in parallel with source 206B and act as an energy buffer for source 206B, as depicted in FIG. 4E, or energy source 206B can be configured to utilize a HED capacitor in parallel with another energy source (e.g., a battery or fuel cell), as depicted in FIG. 4F.

[0096] 6B and 6C are schematic diagrams depicting exemplary embodiments of converters 202B and 202C, respectively. Converter 202B includes switch network portions 601 and 602A. Portion 601, in a similar manner to converter 202A, is configured as a full bridge and includes switches S3-S6 configured to selectively couple IO1 and IO2 to either IO3 or IO4, thereby varying the output voltage of module 108B. Portion 602A is configured as a half bridge and includes switches S1 and S2 coupled between ports IO1 and IO2. A coupled inductor L C However, switch portion 602A is connected between port IO5 and node 1, which exists between switches S1 and S2, so that it is a bidirectional converter that can regulate (boost or buck) voltage (or conversely, current). Switch portion 602A is connected between port IO5 and node 1, which exists between switches S1 and S2, so that it is at a voltage that is effectively zero potential, +V DC, referenced to port IO2. L2Two different voltages can be generated at node 1, ie, 0 and 0. The current drawn from or input to energy source 202B can be controlled by using, for example, pulse width modulation techniques or hysteretic control methods to commutate switches S1 and S2 through coupled inductor L. C The voltage at the output of the power supply can be controlled by adjusting the voltage at the output of the power supply. Other techniques can also be used.

[0097] Converter 202C differs from that of 202B because switch portion 602B includes switches S1 and S2 configured as a half-bridge and coupled between ports IO5 and IO2. C However, switch portion 602B is connected between port IO1 and node 1, which exists between switches S1 and S2, so as to be configured to regulate the voltage.

[0098] Control system 102 or LCD 114 can independently control each switch of converters 202B and 202C via control input line 118-3 to each gate. In these embodiments and that of FIG. 6A, LCD 114 (rather than MCD 112) generates the switching signals for the converter switches. Alternatively, MCD 112 can also generate the switching signals, which can be communicated directly to the switches or relayed by LCD 114.

[0099] In embodiments in which module 108 includes more than two energy sources 206, converters 202B and 202C can be scaled accordingly, such that each additional energy source 206B is coupled to an additional IO port that leads to an additional switch network portion 602A or 602B, depending on the needs of the particular source. For example, dual source converter 202 can include both switch portions 202A and 202B.

[0100] A module 108 with multiple energy sources 206 can perform additional functions such as energy sharing between sources 206, energy capture from within the application (e.g., regenerative braking), charging a primary source with a secondary source even while the overall system is in a discharge state, and active filtering of the module output. Active filtering functions can also be performed by modules with typical electrolytic capacitors in place of secondary energy sources. Examples of these functions are described in further detail in International Application No. PCT / US20 / 25366, filed March 27, 2020, and entitled "Module-Based Energy Systems Capable of Cascaded and Interconnected Configurations, and Methods Related Thereto," and International Publication No. WO2019 / 183553, filed March 22, 2019, and entitled "Systems and Methods for Power Management and Control," both of which are incorporated herein by reference in their entireties for all purposes.

[0101] Each module 108 can be configured to supply one or more auxiliary loads using its one or more energy sources 206. An auxiliary load is a load that requires a lower voltage than the primary load 101. Examples of an auxiliary load can be, for example, the on-board electrical network of an electric vehicle or the HVAC system of an electric vehicle. A load of the system 100 can be, for example, an electric vehicle motor or one of the phases of an electrical grid. This embodiment can allow for a complete decoupling between the electrical characteristics of the energy source (terminal voltage and current) and the electrical characteristics of the load.

[0102] 3C is a block diagram depicting an exemplary embodiment of module 108C configured to supply power to first and second auxiliary loads 301 and 302. Module 108C includes energy source 206, energy buffer 204, and converter 202B coupled together in a manner similar to that of FIG. 3B. First auxiliary load 301 requires a voltage comparable to that supplied by source 206. Load 301 is coupled to IO ports 3 and 4 of module 108C, which are in turn coupled to ports IO1 and IO2 of source 206. Source 206 can output power to both power connection 110 and load 301. Second auxiliary load 302 requires a constant voltage lower than that of source 206. Load 302 is coupled to IO ports 5 and 6 of module 108C, which are coupled to ports IO5 and IO2, respectively, of converter 202B. Converter 202B includes a coupled inductor L coupled to port IO5 (FIG. 6B). C The energy provided by the source 206 can be supplied to the load 302 through the switch portion 602 of the converter 202B. The load 302 has an input capacitor (a capacitor can be added to the module 108C if not applicable), and therefore the switches S1 and S2 are connected to the coupled inductor L C It is assumed that the voltage at source 206 is rectified to regulate the voltage and current through it, thus producing a stable constant voltage for load 302. This regulation allows the voltage of source 206 to be stepped down to a lower magnitude voltage required by load 302.

[0103] Module 108C can thus be configured to supply one or more first auxiliary loads in the manner described with respect to load 301, with one or more first loads coupled to IO ports 3 and 4. Module 108C can also be configured to supply one or more second auxiliary loads in the manner described with respect to load 302. If multiple second auxiliary loads 302 are present, then for each additional load 302, module 108C can be scaled with additional dedicated module output ports (such as 5 and 6), additional dedicated switch sections 602, and additional converter IO ports coupled to the additional sections 602.

[0104] Energy source 206 can therefore supply power for any number of auxiliary loads (e.g., 301 and 302) as well as a corresponding portion of the system output power required by primary load 101. The power flow from source 206 to the various loads can be adjusted as desired.

[0105] The module 108 can be configured to supply the first and / or second auxiliary loads (FIG. 3C) using two or more energy sources 206 (FIG. 3B) as needed, through the addition of switch portion 602 and converter port IO5 for each additional source 206B or second auxiliary load 302. Additional module IO ports (e.g., 3, 4, 5, 6) can be added as needed. The module 108 can also be configured as an interconnect module to exchange energy between two or more arrays, two or more packs, or two or more systems 100 as further described herein (e.g., for balancing). This interconnect functionality can likewise be combined with multiple source and / or multiple auxiliary load supply capabilities.

[0106] The control system 102 may perform various functions for the components of the modules 108A, 108B, and 108C. These functions may include managing the utilization (amount of usage) of each energy source 206, protecting the energy buffer 204 from overcurrent, overvoltage, and high temperature conditions, and controlling and protecting the converter 202.

[0107] For example, to manage (e.g., adjust by increasing, decreasing, or maintaining) the utilization of each energy source 206, LCD 114 can receive one or more monitored voltages, temperatures, and currents from each energy source 206 (or monitor circuitry). The monitored voltages can be at least one, and preferably all, of the voltage of each basic component independent of the other components of source 206 (e.g., each individual battery cell, HED capacitor, and / or fuel cell), or the voltage of the group of basic components as a whole (e.g., the voltage of the battery array, HED capacitor array, and / or fuel cell array). Similarly, the monitored temperatures and currents can be at least one, and preferably all, of the temperature and current of each basic component independent of the other components of source 206, or the temperature and current of the group of basic components as a whole, or any combination thereof. The monitored signals may be status information with which LCD 114 may do one or more of the following: calculate or determine the actual capacity, actual state of charge (SOC), and / or state of health (SOH) of a basic component or group of basic components, set or output a warning or alarm indication based on the monitored and / or calculated status information, and / or transmit status information to MCD 112. LCD 114 may receive control information (e.g., modulation index, synchronization signal) from MCD 112 and use this control information to generate switch signals for converter 202 that manage the utilization of source 206.

[0108] To protect the energy buffer 204, the LCD 114 can receive one or more monitored voltages, temperatures, and currents from the energy buffer 204 (or monitor circuitry). The monitored voltages are monitored for each basic component (e.g., C EB , C EB1 , C EB2 , L EB1 , L EB2 , D EB ) or the voltage of the group of basic components of buffer 204 as a whole (e.g., between IO1 and IO2 or between IO3 and IO4). Similarly, the monitored temperatures and currents can be at least one, preferably all, of the temperature and current of each basic component of buffer 204 independent of the other components, or the temperature and current of the group of basic components of buffer 204 as a whole, or any combination thereof. The monitored signals can be status information with which LCD 114 can do one or more of the following: set or output a warning or alarm indication, communicate status information to MCD 112, or control converter 202 can adjust (increase or decrease) the utilization of source 206 and module 108 as a whole for buffer protection.

[0109] To control and protect the converter 202, the LCD 114 can receive control information (e.g., a modulated reference signal, or a reference signal and a modulation index) from the MCD 112, which can be used within the LCD 114 to generate control signals for each switch (e.g., S1-S6) using PWM techniques. The LCD 114 can receive current feedback signals from current sensors in the converter 202, which can be used for overcurrent protection, along with one or more fault status signals from the converter switch driver circuits (not shown), which can carry information about the fault status (e.g., short-circuit or open-circuit failure mode) of all switches in the converter 202. Based on this data, the LCD 114 can manage the utilization of the module 108 and potentially make decisions regarding the combination of switching signals to be applied to bypass or disconnect the converter 202 (and the entire module 108) from the system 100.

[0110] When controlling module 108C, which supplies second auxiliary load 302, LCD 114 displays one or more monitored voltages within module 108C (e.g., the voltage between IO ports 5 and 6) and one or more monitored currents (e.g., the current in load 302, the voltage across coupled inductor L C Based on these signals, the LCD 114 can adjust the switching cycles of S1 and S2 to control (and stabilize) the voltage to the load 302 (e.g., by adjusting the modulation index or reference waveform). (Example of a cascaded energy system topology)

[0111] Two or more modules 108 can be coupled together in a cascaded array that outputs a voltage signal formed by the superposition of discrete voltages generated by each module 108 in the array. FIG. 7A is a block diagram depicting an exemplary embodiment of a topology for system 100, in which N modules 108-1, 108-2, . . . 108-N are coupled together in series to form a series array 700. In this and all embodiments described herein, N can be any integer greater than 1. Array 700 includes a first system IO port SI01 and a second system IO port SI02 across which the array output voltage is generated. Array 700 can be used as a DC or single-phase AC energy source for DC or AC single-phase loads that may be connected to SI01 and SI02 of array 700. FIG. 8A is a voltage versus time plot depicting an exemplary output signal produced by a single module 108 with a 48-volt energy source. FIG. 8B is a voltage versus time plot depicting an exemplary single-phase AC output signal generated by an array 700 having six 48V modules 108 coupled in series.

[0112] System 100 can be arranged in a variety of different topologies to meet the varying needs of an application. System 100 can provide multi-phase power (e.g., 2-phase, 3-phase, 4-phase, 5-phase, 6-phase, etc.) to a load through the use of multiple arrays 700, with each array generating an AC output signal having a different phase angle.

[0113] FIG. 7B is a block diagram depicting system 100 with two arrays 700-PA and 700-PB coupled together. Each array 700 is one-dimensional and formed by a series connection of N modules 108. Each of the two arrays 700-PA and 700-PB can generate a single-phase AC signal, with the two AC signals having different phase angles PA and PB (e.g., 180 degrees apart). IO port 1 of module 108-1 of each array 700-PA and 700-PB can form or be connected to system IO ports SIO1 and SIO2, respectively, which can then serve as the first output of each array, which can provide two-phase power to a load (not shown). Alternatively, ports SIO1 and SIO2 can be connected to provide single-phase power from the two parallel arrays. IO port 2 of module 108-N of each array 700-PA and 700-PB, on the opposite end of the array from system IO ports SIO1 and SIO2, can serve as a second output for each array 700-PA and 700-PB, and can be coupled together at a common node that can optionally be used, as desired, for an additional system IO port SIO3, which can serve as a neutral. This common node can be referred to as a rail, and IO port 2 of module 108-N of each array 700 can be referred to as being on the rail side of the array.

[0114] 7C is a block diagram depicting system 100 with three arrays 700-PA, 700-PB, and 700-PC coupled together. Each array 700 is one-dimensional and formed by a series connection of N modules 108. Each of the three arrays 700-1 and 700-2 can generate a single-phase AC signal, with the three AC signals having different phase angles PA, PB, and PC (e.g., 120 degrees apart). IO port 1 of module 108-1 of each array 700-PA, 700-PB, and 700-PC can form or be connected to system IO ports SIO1, SIO2, and SIO3, respectively, which can then provide three-phase power to a load (not shown). IO ports 2 of modules 108-N of each array 700-PA, 700-PB, and 700-PC can be coupled together in a common node, which can optionally be used, as desired, for an additional system IO port SIO4, which acts as a neutral.

[0115] 7B and 7C can be extended to systems 100 that generate power in even more phases. For example, a non-exhaustive list of additional examples includes a system 100 having four arrays 700, each configured to generate a single-phase AC signal having a different phase angle (e.g., 90 degrees apart), a system 100 having five arrays 700, each configured to generate a single-phase AC signal having a different phase angle (e.g., 72 degrees apart), and a system 100 having six arrays 700, each configured to generate a single-phase AC signal having a different phase angle (e.g., 60 degrees apart).

[0116] System 100 can be configured such that arrays 700 are interconnected at electrical nodes between modules 108 within each array. Figure 7D is a block diagram depicting system 100 with three arrays 700-PA, 700-PB, and 700-PC coupled together in a combined series and delta arrangement. Each array 700 includes a first series connection of M modules 108 (where M is two or more) coupled with a second series connection of N modules 108 (where N is two or more). The delta configuration is formed by the interconnections between the arrays, which can be placed in any desired location. In this embodiment, IO port 2 of module 108-(M+N) of array 700-PC is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PA, IO port 2 of module 108-(M+N) of array 700-PB is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PC, and IO port 2 of module 108-(M+N) of array 700-PA is coupled to IO port 2 of module 108-M and IO port 1 of module 108-(M+1) of array 700-PB.

[0117] FIG. 7E is a block diagram depicting system 100 with three arrays 700-PA, 700-PB, and 700-PC coupled together in a combined series and delta arrangement. This embodiment is similar to that of FIG. 7D but with a different cross-connection. In this embodiment, IO port 2 of module 108-M of array 700-PC is coupled to IO port 1 of module 108-1 of array 700-PA, IO port 2 of module 108-M of array 700-PB is coupled to IO port 1 of module 108-1 of array 700-PC, and IO port 2 of module 108-M of array 700-PA is coupled to IO port 1 of module 108-1 of array 700-PB. The arrangements of FIGS. 7D and 7E can be implemented with as few as two modules in each array 700. The combined delta and series configuration allows for an effective exchange of energy between all modules 108 of the system (phase-to-phase balance) and the phases of the grid or load, and also allows for a reduction in the total number of modules 108 in the array 700 to obtain the desired output voltage.

[0118] In the embodiments described herein, it is advantageous for the number of modules 108 to be the same in each array 700 in system 100, but that is not required, and different arrays 700 can have different numbers of modules 108. Furthermore, each array 700 can have modules 108 that are all of the same configuration (e.g., all modules are 108A, all modules are 108B, all modules are 108C, etc.) or that are of different configurations (e.g., one or more modules are 108A, one or more modules are 108B, one or more modules are 108C, etc.). Accordingly, the range of topologies of system 100 covered herein is broad. Exemplary Embodiments of Control Methodologies

[0119] As mentioned, control of the system 100 can be implemented according to various methodologies, such as hysteresis or PWM. Some examples of PWM include space vector modulation and sinusoidal pulse width modulation, where the switching signals for the converter 202 are generated using a phase-shifted carrier technique that continuously rotates the utilization of each module 108, distributing power equally between them.

[0120] 8C-8F are plots depicting an exemplary embodiment of a phase-shifted PWM control methodology that can generate multi-level output PWM waveforms using gradually shifted two-level waveforms. An X-level PWM waveform can be generated by summing (X-1) / 2 two-level PWM waveforms. These two-level waveforms can be generated by comparing a reference waveform Vref with a carrier that is gradually shifted by 360° / (X-1). The carrier is triangular, but the embodiment is not so limited. A nine-level example is shown in FIG. 8C (using four modules 108). The carrier is gradually shifted by 360° / (9-1)=45° and compared to Vref. The resulting two-level PWM waveform is shown in FIG. 8E. These two-level waveforms can be used as switching signals for the semiconductor switches (e.g., S1-S6) of the converter 202. As an example, referring to FIG. 8E, for a one-dimensional array 700 including four modules 108, each with a converter 202, the 0° signal is for control of S3 of the first module 108-1, the 180° signal is for S6, the 45° signal is for S3 and the 225° signal for S6 of the second module 108-2, the 90° signal is for S3 of the third module 108-3, the 270° signal is for S6, the 135° signal is for S3 of the fourth module 108-4, and the 315° signal is for S6. The signal for S3 is complementary to S4, with sufficient dead time to avoid shoot-through of each half-bridge, and the signal for S5 is complementary to S6. FIG. 8F depicts an exemplary single-phase AC waveform produced by the superposition (summation) of the output voltages from the four modules 108.

[0121] An alternative is to utilize both positive and negative reference signals along with the first (N-1) / 2 carriers. A nine-level embodiment is shown in FIG. 8D. In this embodiment, the 0° to 135° switching signal (FIG. 8E) is generated by comparing +Vref to the 0° to 135° carrier of FIG. 8D, and the 180° to 315° switching signal is generated by comparing -Vref to the 0° to 135° carrier of FIG. 8D. However, the comparison logic in the latter case is reversed. Other techniques, such as a state machine decoder, can also be used to generate the gate signals for the switches of converter 202.

[0122] In multi-phase system embodiments, the same carrier can be used for each phase, or the set of carriers can be shifted as a whole for each phase. For example, in a three-phase system with a single reference voltage (Vref), each array 700 can use the same number of carriers with the same relative offsets as shown in FIGS. 8C and 8D, but the carrier for the second phase is shifted 120 degrees compared to the carrier for the first phase, and the carrier for the third phase is shifted 240 degrees compared to the carrier for the first phase. If different reference voltages are available for each phase, phase information can be conveyed in the reference voltage, and the same carrier can be used for each phase. While in many cases the carrier frequency will be fixed, in some exemplary embodiments the carrier frequency can be adjusted, which can help reduce losses in the EV motor under high current conditions.

[0123] An appropriate switching signal can be provided to each module by the control system 102. For example, the MCD 112 can provide Vref and an appropriate carrier signal to each LCD 114 depending on the module or modules 108 that the LCD 114 controls, and the LCD 114 can then generate the switching signal. Alternatively, all LCDs 114 in the array can provide all carrier signals, and the LCD can select the appropriate carrier signal.

[0124] The relative utilization of each module 108 can be adjusted based on the status information to perform one or more parameter balancing, as described herein. Parameter balancing can involve adjusting utilization to minimize parameter divergence over time compared to a system in which individual module utilization adjustments are not performed. Utilization can be the relative amount of time a module 108 is discharging when the system 100 is in a discharging state, or the relative amount of time a module 108 is charging when the system 100 is in a charging state.

[0125] As described herein, modules 108 can be balanced relative to other modules in an array 700, which may be referred to as intra-array or intra-phase balancing, and different arrays 700 can also be balanced relative to each other, which may be referred to as inter-array or inter-phase balancing. Arrays 700 of different subsystems can also be balanced relative to each other. The control system 102 can simultaneously perform any combination of intra-phase balancing, inter-phase balancing, utilization of multiple energy sources within a module, active filtering, and auxiliary load supply.

[0126] 9A is a block diagram depicting an example embodiment of an array controller 900 of the control system 102 for a single-phase AC or DC array. The array controller 900 may include a peak detector 902, a divider 904, and an intra-phase (or intra-array) balance controller 906. The array controller 900 may receive as inputs a reference voltage waveform (Vr) and status information (e.g., state of charge (SOCi), temperature (Ti), capacity (Qi), and voltage (Vi)) for each of the N modules 108 in the array and generate as outputs a normalized reference voltage waveform (Vrn) and a modulation index (Mi). The peak detector 902 detects the peak (Vpk) of Vr, which may be specific to the phase on which the controller 900 is operating and / or balancing. The divider 904 generates Vrn by dividing Vr by the detected Vpk. The intra-phase balance controller 906 uses Vpk along with status information (eg, SOCi, Ti, Qi, Vi, etc.) to generate a modulation index Mi for each module 108 in the array 700 being controlled.

[0127] The modulation index and Vrn can be used to generate a switching signal for each converter 202. The modulation index can be a number between zero and one (inclusive). For a particular module 108, a normalized reference Vrn can be modulated or scaled by Mi, and this modulated reference signal (Vrnm) can be used as Vref (or −Vref) according to the PWM techniques described with respect to FIGS. 8C-8F or other techniques. In this manner, the modulation index can be used to control the PWM switching signals provided to the converter switching circuitry (e.g., S3-S6 or S1-S6) and thus regulate the operation of each module 108. For example, a module 108 controlled to maintain normal or full operation may receive a Mi of one, while a module 108 controlled to operate less than normal or full may receive a Mi of less than one, and a module 108 controlled to cease power output may receive a Mi of zero. This operation can be performed in a variety of ways by the control system 102, such as by the MCD 112 outputting Vrn and Mi to the appropriate LCD 114 for modulation and switch signal generation, by the MCD 112 performing the modulation and outputting the modulated Vrnm to the appropriate LCD 114 for switch signal generation, or by the MCD 112 performing the modulation and switch signal generation and outputting the switch signal directly to the LCD or converter 202 of each module 108. Vrn can be transmitted continuously, with Mi transmitted at regular intervals, such as once per period of Vrn or once per minute.

[0128] The controller 906 can generate Mi for each module 108 using any type or combination of types of status information described herein (e.g., SOC, temperature (T), Q, SOH, voltage, current). For example, using SOC and T, a module 108 can have a relatively high Mi if its SOC is relatively high and its temperature is relatively low compared to other modules 108 in the array 700. If either of the SOCs is relatively low or T is relatively high, that module 108 can have a relatively low Mi and result in less utilization than other modules 108 in the array 700. The controller 906 can determine Mi such that the sum of the module voltages does not exceed Vpk. For example, Vpk is the sum of the products of the voltages of each module's sources 206 and Mi for that module (e.g., Vpk=M1V1+M2V2+M3V3...+M N V N etc.) Different combinations of modulation indexes, and therefore respective voltage contributions by the modules, can be used, but the total generated voltage should remain the same.

[0129] The controller 900 can control operation so that the SOC of the energy sources within each module remains balanced or, if unbalanced, converges to a balanced condition, and / or the temperature of the energy sources or other components (e.g., energy buffers) within each module 108 remains balanced or, if unbalanced, converges to a balanced condition, as long as it does not prevent the system from achieving its power output requirements at any time (e.g., during maximum acceleration of an EV). Power flow into and out of modules can be adjusted so that capacitance differences between sources do not cause SOC deviations. SOC and temperature balancing can indirectly cause some balancing of SOH. While voltage and current can be balanced directly if desired, in many embodiments, the primary goal of the system is to balance SOC and temperature, and SOC balancing can lead to voltage and current balancing in a highly symmetrical system where modules are of similar capacitance and impedance.

[0130] Since balancing all parameters may not be possible simultaneously (e.g., balancing one parameter may further unbalance another), a combination of balancing any two or more parameters (SOC, T, Q, SOH, V, I) may be applied, with priority given to one or the other, depending on the requirements of the application. Priority in balancing may be given to SOC over the other parameters (T, Q, SOH, V, I), with exceptions being allowed if one of the other parameters (T, Q, SOH, V, I) reaches a critical imbalance condition outside the threshold.

[0131] Balancing between arrays 700 of different phases (or arrays of the same phase, e.g., if parallel arrays are used) can be performed in parallel with intra-phase balancing. FIG. 9B depicts an exemplary embodiment of an Ω-phase (or Ω-array) controller 950 configured for operation in an Ω-phase system 100 having at least Ω arrays 700, where Ω is any integer greater than 1. The controller 950 may include one inter-phase (or inter-array) controller 910, Ω intra-phase balance controllers 906-PA...906-PΩ for phases PA-PΩ, and a peak detector 902 and divider 904 ( FIG. 9A ) for generating a normalized reference VrnPA-VrnPΩ from each phase-specific reference VrPA-VrPΩ. The intra-phase controller 906 may generate Mi for each module 108 of each array 700, as described with respect to FIG. 9A . The phase balance controller 910 is configured or programmed to balance the sides of the modules 108 across the entire multidimensional system, for example, between arrays of different phases. This can be achieved through injecting a common mode into the phases (e.g., neutral point shift), or through the use of interconnection modules (described herein), or both. Common mode injection involves introducing a phase and amplitude shift into the reference signal VrPA-VrPΩ to generate a normalized waveform VrnPA-VrnPΩ, compensating for imbalances within one or more arrays, and is further described in International Application No. PCT / US20 / 25366, incorporated herein.

[0132] Controllers 900 and 950 (and balance controllers 906 and 910) can be implemented in hardware, software, or a combination thereof within control system 102. Controllers 900 and 950 can be implemented within MCD 112, partially or completely distributed among LCD 114, or can be implemented as discrete controllers independent of MCD 112 and LCD 114. Exemplary Embodiments of an Interconnect (IC) Module

[0133] A module 108 can be connected between modules of different arrays 700 to exchange energy between arrays, act as a source for auxiliary loads, or both. Such a module is referred to herein as an interconnect (IC) module 108. The IC module 108 can be implemented in any of the module configurations already described (108A, 108B, 108C) and others to be described herein. The IC module 108 can include any number of one or more energy sources, optional energy buffers, switch circuitry for supplying energy to one or more arrays and / or power to one or more auxiliary loads, control circuitry (e.g., local control devices), and monitor circuitry for collecting status information about the IC module itself or its various loads (e.g., SOC of the energy source, temperature of the energy source or energy buffer, capacity of the energy source, SOH of the energy source, voltage and / or current measurements for the IC module, voltage and / or current measurements for the auxiliary loads, etc.).

[0134] 10A is a block diagram depicting an example embodiment of system 100 capable of producing Ω-phase power using Ω arrays 700-PA-700-PΩ, where Ω can be any integer greater than 1. In this and other embodiments, IC module 108IC can be located on the rail side of array 700 such that the array 700 to which module 108IC is connected (in this embodiment, array 700-PA-700-PΩ) is electrically connected between module 108IC and the output to the load (e.g., SIO1-SIOΩ). Here, module 108IC has Ω IO ports for connection to IO port 2 of each module 108-N of array 700-PA-700-PΩ. In the configuration depicted here, module 108IC can perform phase balancing by selectively connecting one or more energy sources of module 108IC to one or more of array 700-PA-700-PΩ (or to no output, or equally to all outputs, if phase balancing is not required). System 100 can be controlled by control system 102 (not shown, see FIG. 1A).

[0135] FIG. 10B is a schematic diagram depicting an exemplary embodiment of module 108IC. In this embodiment, module 108IC includes an energy source 206 connected to an energy buffer 204, which in turn is connected to a switch network 603. Switch network 603 may include switch network units 604-PA-604-PΩ to independently connect energy source 206 to each of arrays 700-PA-700-PΩ. Various switch configurations can be used for each unit 604, which in this embodiment is configured as a half-bridge with two semiconductor switches S7 and S8. Each half-bridge is controlled by control line 118-3 from LCD 114. This configuration is similar to module 108A described with reference to FIG. 3A. As described with reference to converter 202, switch network 603 can be configured with any switch type (e.g., MOSFET, IGBT, silicon, GaN, etc.) in any arrangement suitable for the application requirements.

[0136] The switch network unit 604 is coupled between the positive and negative terminals of the energy source 206 and has an output connected to an IO port of the module 108 IC. The unit 604-PA-604-PΩ is connected by the control system 102 to a voltage +V IC or -V ICto their respective module I / O ports 1-Ω. The control system 102 can control the switch circuitry 603 according to any desired control technique, including the PWM and hysteresis techniques described herein. Here, the control circuitry 102 is implemented as an LCD 114 and an MCD 112 (not shown). The LCD 114 can receive monitoring data or status information from the monitor circuitry of the module 108 IC. This monitoring data and / or other status information derived from this monitoring data can be output to the MCD 112 for use in system control, as described herein. The LCD 114 can also receive timing information (not shown) for purposes of synchronization of the modules 108 of the system 100 and one or more carrier signals (not shown), such as sawtooth signals (FIGS. 8C-8D) used in PWM.

[0137] Due to phase-to-phase balance, relatively more energy from source 206 can be supplied to any one or more of arrays 700-PA-700-PΩ that are at a relatively low state of charge compared to the other arrays 700. This complementary energy supply to a particular array 700 allows the energy output of those cascaded modules 108-1-108-N within that array 700 to be reduced relative to the unsupplied phase arrays.

[0138] For example, in some exemplary embodiments applying PWM, the LCD 114 can be configured to receive (from the MCD 112) a normalized voltage reference signal (Vrn) for each of the one or more arrays 700 to which its module 108 IC is coupled, e.g., VrnPA-VrnPΩ. The LCD 114 can also receive modulation indices MiPA-MiPΩ for the switch units 604-PA-604-PΩ from the MCD 112, respectively, for each of the arrays 700. The LCD 114 can modulate (e.g., multiply) each respective Vrn with the modulation index (e.g., VrnA is multiplied by MiA) for the switch section directly coupled to its array, and then use the carrier signal to generate the control signal for each switch unit 604. In other embodiments, the MCD 112 can perform the modulation and output the modulated voltage reference waveform for each unit 604 directly to the LCD 114 of the module 108 IC. In yet other embodiments, all processing and modulation may occur by a single control entity, which may output control signals directly to each unit 604 .

[0139] This switching can be modulated so that power from the energy source 206 can be supplied to the array 700 at appropriate intervals and durations. Such a methodology can be implemented in a variety of ways.

[0140] Based on collected status information about the system 100, such as the current capacity (Q) and SOC of each energy source in each array, the MCD 112 can determine a total charge for each array 700 (e.g., the total charge for an array can be determined as the sum of the capacities times the SOCs for each module in that array). The MCD 112 can determine whether a balanced or unbalanced condition exists (e.g., through the use of relative difference thresholds and other metrics described herein) and generate modulation indices MiPA-MiPΩ for each switch unit 604-PA-604-PΩ, as appropriate.

[0141] During balanced operation, Mi per switch unit 604 can be set to a value that causes the same or similar amount of net energy to be supplied by the energy source 206 and / or energy buffer 204 to each array 700 over time. For example, Mi per switch unit 604 can be the same or similar and can be set to a level or value that causes the module 108IC to perform a net or time-averaged discharge of energy into one or more arrays 700-PA-700-PΩ during balanced operation, such that the module 108IC drains at the same rate as the other modules 108 in the system 100. In some embodiments, Mi per unit 604 can be set to a level or value that causes no net or time-averaged discharge of energy (causing a net energy discharge of zero) during balanced operation. This can be useful if the module 108IC has a lower total charge than the other modules in the system.

[0142] If an unbalanced condition occurs between arrays 700, the modulation index of system 100 can be adjusted to cause convergence toward a balanced condition or minimize further divergence. For example, control system 102 can cause module 108 to discharge more into an array 700 with a lower charge than the others, and cause modules 108-1-108-N of that lower array 700 to discharge relatively less (e.g., on a time-averaged basis). The relative net energy contributed by module 108 increases compared to modules 108-1-108-N of the supported array 700 and compared to the amount of net energy the other arrays contribute to module 108. This can be accomplished by increasing Mi for the switch unit 604 feeding that low array 700, and by decreasing the modulation indexes of the modules 108-1-108-N of the low array 700 in a manner that maintains Vout for that low array at an appropriate or required level and keeps the modulation indexes for the other switch units 604 feeding other higher arrays relatively unchanged (or decreases them).

[0143] 10A-10B can be used alone to provide phase-to-phase or array-to-array balancing for a single system, or can be used in combination with one or more other modules 108IC, each having an energy source and one or more switch portions 604 coupled to one or more arrays. For example, a module 108IC with Ω switch portions 604 coupled to Ω different arrays 700 can be combined with a second module 108IC having one switch portion 604 coupled to one array 700, such that the two modules are combined to feed a system 100 having Ω+1 arrays 700. Any number of modules 108IC can be combined in this manner, each coupled to one or more arrays of the system 100.

[0144] Additionally, the IC module can be configured to exchange energy between two or more subsystems of system 100. FIG. 10C is a block diagram depicting an example embodiment of system 100 with a first subsystem 1000-1 and a second subsystem 1000-2 interconnected by an IC module. Specifically, subsystem 1000-1 is configured to supply three-phase power PA, PB, and PC to a first load (not shown) using system I / O ports SIO1, SIO2, and SIO3, while subsystem 1000-2 is configured to supply three-phase power PD, PE, and PF to a second load (not shown) using system I / O ports SIO4, SIO5, and SIO6, respectively. For example, subsystems 1000-1 and 1000-2 can be configured as different packs supplying power for different motors of an EV or as different racks supplying power for different microgrids.

[0145] In this embodiment, each module 108IC is coupled to the first subsystem array 1000-1 (via IO port 1) and the first subsystem array 1000-2 (via IO port 2), and each module 108IC can be electrically connected to each other module 108IC using I / O ports 3 and 4, which are coupled to the energy source 206 of each module 108IC, as described with respect to module 108C in FIG. 3C. This connection places the sources 206 of modules 108IC-1, 108IC-2, and 108IC-3 in parallel; thus, the energy stored and supplied by the modules 108IC is pooled together through this parallel arrangement. Other arrangements, such as a serial connection, can also be used. The modules 108IC are housed within the common enclosure of subsystem 1000-1; however, the interconnection module can be external to the common enclosure and physically located as an independent entity between the common enclosures of both subsystems 1000-1.

[0146] Each module 108IC has a switch unit 604-1 coupled to IO port 1 and a switch unit 604-2 coupled to I / O port 2, as described with respect to FIG. 10B . Thus, for balancing between subsystems 1000 (e.g., pack-to-pack or rack-to-rack balancing), a particular module 108IC can supply relatively more energy to one or both of the two arrays to which it is connected (e.g., module 108IC-1 can supply array 700-PA and / or array 700-PD). Control circuitry can monitor relative parameters (e.g., SOC and temperature) of the arrays of different subsystems and adjust the energy output of the IC modules to compensate for imbalances between arrays or phases of different subsystems, in a manner similar to compensating for imbalances between two arrays of the same rack or pack as described herein. Because all three modules 108IC are in parallel, energy can be efficiently exchanged between every array of system 100. In this embodiment, each module 108 IC supplies two arrays 700, although other configurations can be used, including a single IC module for all arrays in system 100 and a configuration with one dedicated IC module per array 700 (e.g., six IC modules for six arrays, each IC module having one switch unit 604). In all cases, with multiple IC modules, energy sources can be coupled together in parallel to share energy as described herein.

[0147] In systems with IC modules between the phases, phase-to-phase balancing can also be performed by neutral point shifting (or common-mode injection), as described above. Such a combination allows for more robust and flexible balancing under a wider range of operating conditions. System 100 can determine appropriate situations under which phase-to-phase balancing should be performed using neutral point shifting alone, phase-to-phase energy injection alone, or a combination of both simultaneously.

[0148] The IC modules can also be configured to supply power to one or more auxiliary loads 301 (at the same voltage as source 206) and / or one or more auxiliary loads 302 (at a stepped-down voltage from source 302). FIG. 10D is a block diagram depicting an example embodiment of a three-phase system 100A with two modules 108IC connected to perform phase-to-phase balancing and supply auxiliary loads 301 and 302. FIG. 10E is a schematic diagram depicting this example embodiment of system 100 with coordination placed on modules 108IC-1 and 108IC-2. Here, control circuitry 102 is again implemented as an LCD 114 and an MCD 112 (not shown). The LCD 114 receives monitoring data (e.g., SOC of ES1, temperature of ES1, Q of ES1, voltage of auxiliary loads 301 and 302, etc.) from the module 108IC and can output this and / or other monitoring data to the MCD 112 for use in system control, as described herein. Each module 108IC can include a switch portion 602A (or 602B, as described with respect to FIG. 6C ) for each load 302 being supplied by that module, and each switch portion 602 can be controlled by the LCD 114, either independently or based on a control input from the MCD 112, to maintain the required voltage level for the load 302. In this embodiment, each module 108IC includes switch portions 602A connected together and supplying one load 302, although that is not required.

[0149] FIG. 10F is a block diagram depicting another example embodiment of a three-phase system configured to supply power to one or more auxiliary loads 301 and 302 using modules 108IC-1, 108IC-2, and 108IC-3. In this embodiment, modules 108IC-1 and 108IC-2 are configured in the same manner as described with respect to FIGS. 10D-10E. Module 108IC-3 is configured in a simple auxiliary role and does not actively inject voltage or current into any array 700 of system 100. In this embodiment, module 108IC-3 may have converters 202B, C (FIGS. 6B-6C) configured like module 108C of FIG. 3B with one or more auxiliary switch portions 602A but omitting switch portion 601. Thus, one or more energy sources 206 of module 108IC-3 are interconnected in parallel with those of modules 108IC-1 and 108IC-2, and thus this embodiment of system 100 is configured with additional energy to supply auxiliary loads 301 and 302 and to maintain charge on sources 206A of modules 108IC-1 and 108IC-2 through the parallel connection with sources 206 of module 108IC-3.

[0150] The energy source 206 of each IC module can be at the same voltage and capacity as the sources 206 of the other modules 108-1-108-N in the system, but that is not required. For example, a relatively high capacity may be desirable in embodiments where one module 108 applies energy to multiple arrays 700 (FIG. 10A), allowing the IC module to discharge at the same rate as the modules in the phased array itself. If module 108 also supplies an auxiliary load, even more capacity may be desired to allow the IC module to both supply the auxiliary load and discharge at relatively the same rate as the other modules.

[0151] The above-described embodiments described with respect to FIGS. 1A-10F can be used in conjunction with all of the following embodiments relating to the implementation of system 100 in applications having cooling systems and removable and replaceable modules for system 100. Exemplary Embodiments of a Cooling System

[0152] Because the amount of heat generated by system 100 during operation can be significant, it is often necessary to provide a cooling system capable of circulating coolant in close proximity to various elements of system 100 and / or the EV's motor and any other elements requiring cooling. FIG. 11A depicts an example of a cooling array 1100, in which coolant is pumped through various elements of array 1100 by pump 1101. The coolant can be circulated such that components with the greatest cooling requirements are required first and those with more moderate thermal requirements are cooled last. For example, in this embodiment, pump 1101 first circulates coolant to battery module 206, which may require coolant at a relatively low temperature of 20-30° C., then to the power converter 202 and control (e.g., LCD 114) electronics 1104 of module 108, which may require coolant at a relatively high temperature of up to 40 or 50° C., and finally to one or more motors 1106, which may require coolant at even higher temperatures below 60° C. After circulating in close proximity to these components and cooling them, the coolant can proceed through heat exchanger 1108 where its temperature is reduced back to a temperature closer to the requirements of the battery module 206, at which point it is circulated through pump 1101 and the loop repeats.

[0153] One or more of the subsystems 1000 described herein can be implemented within a common enclosure. An energy storage system contained within a common enclosure is often referred to as a pack, e.g., a battery pack. FIG. 11B depicts an example of a common enclosure 1110 for one or more subsystems of system 100. The common enclosure 1110 contains each of the modules 108 of one or more subsystems and may also include any interconnection modules present. The energy source, energy buffer, converter power electronics (switching network), control electronics, and any other components of the modules would be contained within the common enclosure 1110. For example, see FIG. 11E, where the battery module 206 is located at the bottom and the associated power converter and control electronics 1104 are located above the battery within the enclosure. The common enclosure 1110 can include a bottom enclosure 1112, such as a base, and an opposing top enclosure 1111, such as a lid, both of which can include one or more conduits for circulating coolant through those sides of the enclosures 1111 and 1112 to cool the modules 108. As shown, here coolant from the pump 301 can be circulated to the bottom enclosure 1112 where it passes through a conduit network 1114, like that shown for the top enclosure 1111, thus passing in close proximity to the batteries and providing cooling thereto. The coolant can exit the bottom enclosure 1112, pass to the top enclosure 1111 (either through conduits external to the enclosure 1110 or via conduits on the sides or within the enclosure 1110), and circulate through the conduit network 1114, where it passes in close proximity to and cools the electronics of the modules. The coolant can then exit the top enclosure 1111, where it can proceed to the next component of the system, such as the motor 1106.

[0154] In some embodiments, it is possible to first cool the battery and then subsequently provide coolant only through the top of the enclosure 1111 to cool all sides of the module 108 without cooling the electronics. Figure 11C depicts an example arrangement 320 in which coolant is circulated from the pump 301 to the module 320, where it simultaneously cools both the battery and associated electronics, and then passes to the motor 1106 and heat exchanger 1108. Figure 11D depicts an example embodiment similar to that of Figure 11B, but in which coolant passes only through the conduit network 1114 in the top enclosure.

[0155] FIG. 11E is a perspective view showing an example layout for modules within enclosure 1110. Here, each module is shown as a battery adjacent to its converter (e.g., the first module is battery-1 and converter-1 combined, etc.). Only the top enclosure 1111 is shown here; the sides and bottom of enclosure 1110 and the conduit network within the top enclosure are omitted for clarity. In this example, the converter is placed above the battery, and coolant flows through the top enclosure 1111 above the converter, such that heat from the battery passes upward through the converter and into the top enclosure 1111, where it is removed through the circulating coolant. The reverse configuration can also be implemented, with the converter placed at the bottom and the battery placed above the converter, and heat extracted again through the top enclosure, according to FIG. 11E, or through both the bottom and top, according to FIG. 11B. In yet another embodiment, the converter and battery can be arranged as shown in FIG. 11E or in an inverted configuration, but the coolant can be passed only through the bottom enclosure. In yet another embodiment, the converter and battery can be installed side-by-side, and the coolant can be circulated through the top and / or bottom enclosures. All of the foregoing variations can be implemented with the coolant also passing through a conduit network in the top, bottom, and / or side walls of the enclosure.

[0156] FIG. 11F is a cross-section of an exemplary embodiment in which the converter and control electronics 1108 are positioned above the battery 206. While this embodiment will be described with reference to a conduit 1114 within the top enclosure 1111, the features of this embodiment can also be applied to a conduit 1114 passing through the bottom of the enclosure or the side of the enclosure, as described. In FIG. 11F, the converter and control system electronics 1108 are contained within an electronics housing 1122. The electronics 1108 are mounted on one or more substrates 1124, such as printed circuit boards (PCBs) or insulated metal substrate (IMS) boards, that provide electrical connections passing between the various components. The PCB or IMS is oriented above the electronics 1108 so that the electronics are mounted upside down. The battery 206 is located below the housing 1122 and rests on a base 1126, which may be the bottom enclosure. The battery 206 has positive and negative terminals 1128 located on top of the battery. Electrical connections 1130 extend from terminals 1128 through housing 1122 (or alternatively, its exterior) to the PCB or IMS and / or converter electronics for switching. The PCB or IMS is located immediately adjacent to a heat sink plate 1132 made of a highly thermally conductive material, such as aluminum, aluminum alloy, copper, or steel.

[0157] The upper enclosure 1111 includes a conduit 1114 for the coolant 1136, as described with respect to FIGS. 11B and 11D . The conduit 1114 is made of a highly thermally conductive material, such as aluminum, copper, or steel, and can be shaped with a polygonal cross-section as depicted here, although other shapes, such as oval or circular or a combination of rounded and polygonal shapes, can also be used. The conduit 1114 can be positioned within a channel 1120 in the upper enclosure 1111 that has a shape corresponding to the conduit. For example, if the conduit 1114 has a polygonal cross-section, the channel 1120 can also have a polygonal cross-section, allowing the conduit 1114 to be positioned therein. The upper enclosure 1111 can also be made of a highly thermally conductive material, such as aluminum, copper, or steel. The channel 1120 can be machined or etched into the upper enclosure 1111 and the conduit 1114 can be an interference fit therein.

[0158] As shown here, two sections of conduit 1114 pass through a particular module 108 of system 100. Optionally, an interface layer 1134 can be present between the bottom surface of conduit 1114 and the top surface of heat sink 1132. Interface layer 1134 can be a material with high thermal conductivity and deformability or elasticity to form a continuous and durable contact between heat sink 1132 and the bottom surface of conduit 1114 (as well as the bottom surface of upper enclosure 1111). Interface layer 1134 can be relatively thinner than upper enclosure 1111, and heat sink 1132 and interface layer 1134 can be comprised of, for example, a thermally conductive polymer.

[0159] In this embodiment, the conduits 1114 are shown passing through one module; however, the density of the layout of the conduits 1114 will vary based on the thermal requirements of the application. Preferably, at least one conduit 1114 passes through each module, but that is not required. One conduit 1114 can be shared by two or more modules. The conduits 1114 can be routed through the center of the module, or can be about one-third of the way down the side of the module, as depicted in FIG. 11F, or otherwise.

[0160] 11F can achieve reliable cooling for the embodiments described herein using only the top enclosure of the enclosure 1110. As mentioned, similar arrangements can be installed along the sides and / or bottom of the enclosure 1110 such that the conduits 1114 are adjacent to the bottom of the battery or separated from the bottom of the battery by a second interface layer. Exemplary Embodiments of Removable and Replaceable Modules

[0161] The example topologies described herein can be configured to allow the energy source 206 of each module 108 to be removed from its location within the EV and replaced. This removable and replaceable capability can be used to quickly and conveniently replace a battery (or other energy source) with a relatively low charge capacity for one with a relatively high charge capacity, thus potentially significantly reducing the time required to charge an EV. Such a capability is advantageous for environments where EVs are utilized for extended periods throughout the day, such as fleet operations (e.g., ride-sharing, delivery, or rental cars).

[0162] 12A and 12B depict an exemplary embodiment of an EV 1200 with replaceable battery (or other source) capability. In this embodiment, each side (left and right) of the EV has a single battery access panel or door that is closed during operation of the EV and opened to allow access to the space 1202 that holds the various batteries of the system 100. The battery can have an elongated form factor such that it has a relatively long length and a relatively low height, as will be described in further detail herein. The low height allows the battery to be installed along the bottom of the chassis so that any passenger or driver seats can be set above the battery and its modules without significantly adding to the overall height of the EV 1200. FIG. 12A depicts the EV 1200 with the single battery access door closed, and FIG. 12B depicts the EV 1200 with the battery access door 1201 open, in this case in a raised position. Opening a total of one battery access door exposes battery access space 1202, from which each battery can be removed and replaced with another (or in some cases, an identical battery after charging or repair).

[0163] In the embodiments of FIGS. 12A-12B and also FIG. 13A described below, each battery is configured as a battery module (BM) having multiple cells. The modular energy system includes multiple subsystems for powering different electric motors of the EV 1200. Each battery module is referenced to the subsystem in which it resides, the phase of the array in which it resides, and the level of the array in which the module housing the battery module resides. For example, a battery module associated with the first subsystem, array for phase A of the first subsystem, and a module in level 2 of the array (e.g., module 108-2) is referred to as BM1A2 (battery module, subsystem 1, phase A, level 2). A battery module associated with an interconnection module 108IC configured according to any of the embodiments described herein is referenced by the interconnection module (IC), the battery access door 1201 (L for left, R for right) through which it is accessible, and its status as the number of interconnection modules (e.g., 1, 2, 3). For example, the battery module that is part of the third interconnection module accessible from the left side of the vehicle is referred to as BMICL3. Converter (C) in Figure 13A is referenced in a similar manner.

[0164] FIG. 13A is a cross-sectional top-down view of an exemplary embodiment of an EV 1200 with system 100 therein. In this embodiment, the EV 1200 includes four in-wheel motors 1-4. Battery access doors 1201 are shown on the left and right. System 100 is configured in an electrical arrangement similar to that described with reference to FIG. 13B. In this embodiment, each motor is powered by three arrays, each with three modules 108 therein. System 100 can be configured for any number of modules N in each array, where N is two or more. Here, each module is represented by a battery module coupled with a converter; other components are not shown. The converter can include all electronics associated with the module (including the local control device 114 for that module). Battery-specific electronics, such as a battery management system (BMS), can be located with the battery modules. Power connections between modules are shown in the central region of the EV 1200. These connections can be implemented with insulated bus bars. The insulated bus bars can be arranged along the inside of the converter, along the bottom of the converter, along the top of the converter, or any combination thereof, as shown here, to efficiently transport power. Although not shown, there is also data communication between modules and with the master control device 112.

[0165] Also shown are six IC modules 108IC. Interconnection modules ICL1, ICL2, and ICL3 interconnect the subsystems that supply motors 1 and 2, while interconnection modules ICR1, ICR2, and ICR3 interconnect the subsystems that supply motors 3 and 4. The interconnection modules can be used to supply auxiliary loads (not shown) and to perform phase balancing.

[0166] FIG. 14A is a perspective view depicting an example embodiment of a housing 1402 for the battery module 206 and module electronics. The battery module 206 can be configured with any standard operating voltage (e.g., 24V, 48V, 60V, etc.) and have an elongated form factor. The major dimension (length) shown here can be greater than 18 inches, while the width and height can be 6 inches or less. In other embodiments, the length can be at least twice the width, at least three times the width, at least four times the width, or at least five times the width. In this embodiment, the width is approximately one-half the height. The housing 1402 is attached to guide rails 1404 that can guide the sliding movement of the battery module 206 into electrical connection with the converter and other electronics (e.g., energy buffer 204, LCD 114). The battery module 206 has a positive terminal 1411 as shown and an opposing negative terminal (not shown). The orientation can be reversed, depending on the embodiment. Another configuration, in which both the positive and negative terminals are located on the same side (facing the housing 1402), can also be implemented, as shown in FIG. 14F. The battery module 206 also has a data connection (not shown) to carry information about the battery, such as charge and temperature information, which can mate with an electrical connector, labeled as BMS, on the housing 1402. The battery module 206 can be latched or locked into a locking and connecting position with electronics within the housing 1402. FIG. 14A depicts one exemplary embodiment of a latching mechanism 1406 in the form of a panel that can engage with a protective rail 1404. The panel includes a power connector 1408 (+) that can connect with the positive terminal 1411 of the battery. Another power connector 1409 (-) is shown below the BMS port; this connector can mate with the negative terminal on the battery module 206.

[0167] FIG. 14D depicts the battery module 206 in the process of being slid into (or out of) electrical contact with the electronics within the housing 1402. FIG. 14E depicts the battery module 206 after it has been fully advanced into contact with the electronics and after the latch mechanism 1406 has been lifted to a locked position, forming an electrical connection with the positive terminal of the battery module 206. Power from this connection can be transmitted along the bottom side of the protective rail 1404 to the electronics on the opposite end. In the position of FIG. 14E, the battery module 206 is in a secured position relative to the housing 1402, and all electrical connections between the battery 206 and the electronics within the housing 1402 have been made. The battery module 206 will be in the position depicted in FIG. 14E during operation of the EV.

[0168] To remove a fully or partially discharged battery module 206, the EV's battery access door 1201 can be opened, the latch mechanism 1406 for that battery module 206 can be released, and the battery module 206 can be slid along the protective rails 1404 out of electrical contact with the electronics and removed from the EV 1200 through the open battery access door 1201. In this manner, all battery modules 206 in all modules can be removed and replaced in rapid succession in a matter of minutes (e.g., five minutes or less), converting the EV 1200 from a low charge to a high charge or fully charged one.

[0169] FIG. 14B is an end view depicting the opposite end of the housing 1402, with the BMS and power connector 1409(-) port. Shown here are control and data ports for exchanging information to and from the local control device 114 (not shown) within the housing 1402. Information from this control and data port can be routed to other modules in the system 100 and to the master control device 112 (not shown). Also shown are power connection ports 1 and 2 for connection to other components of the system 100 (e.g., to other modules or motors), depending on the location of the modules within the system 100. See, for example, IO ports 1 and 2 of modules 108A-108C in FIGS. 3A-3C.

[0170] 14C is an end view depicting an end of interconnect module housing 1402. Interconnect module 108IC can be substantially identical to that described with respect to FIGS. 14A, 14B, 14D, 14E, and 14F, but can be configured with additional power connection ports 3, 4, 5, and / or 6 (e.g., IO ports 3-6 of module 108C in FIG. 3C) for supplying power to other interconnect modules 108IC and auxiliary loads 301 and 302 (e.g., FIG. 13B).

[0171] 14A-14F can be implemented in any desired manner. For example, the ports on the battery module 206 can be configured as male ports designed to mate with corresponding female ports on the housing 1402 and latching mechanism 1406, or vice versa. Each of the IO ports shown in FIGS. 14B and 14C can be implemented as male or female ports designed to mate with bus bars or other connectors for carrying data and / or power to and from the housing 1402.

[0172] Without being limited thereto, the present embodiments can be used in conjunction with electric vehicles having a universal EV platform, including powertrain, no drivetrain, in-wheel motors, or a combination, with an energy storage system and one or more motors mounted thereto. The universal EV platform can be an EV base frame or chassis that can be attached to, mated with, or otherwise integrated with any number of EV bodies depending on the particular application, such as automated driverless and passenger-less bodies (e.g., low-voltage applications for automated delivery services), medium-sized bodies (e.g., sedans or coupes or sports cars) for use in applications carrying at least one passenger or driver seat that do not require the transportation of heavy loads (and thus have moderate or medium-voltage requirements), and large-sized bodies (e.g., passenger buses, cargo transport, etc.) for moving multiple passengers and / or large loads with a driver seat (and thus require relatively high-voltage power requirements).

[0173] Various aspects of the present subject matter are described below in a review of and / or as a complement to the previously described embodiments, with emphasis on the interrelationship and interchangeability of the following embodiments. In other words, emphasis is placed on the fact that each feature of the embodiments can be combined with any other feature unless expressly stated or taught otherwise.

[0174] In many embodiments, a modular energy system is provided that is controllable to supply power to a load, the system including a plurality of modules connected together and outputting an AC voltage signal from each module including a superposition of a first output voltage, each module including an energy source and converter electronics connected to the energy source and configured to generate a first output voltage from the energy source; and an enclosure for the plurality of modules, the enclosure configured to pass a coolant through the enclosure to cool the plurality of modules.

[0175] In some embodiments, the enclosure includes a conduit section configured to pass a coolant therethrough. The enclosure can include a channel having a shape corresponding to the shape of the conduit section, with the conduit section positioned within the channel. The conduit section can be an interference fit within the channel. A first module of the plurality of modules can have converter electronics mounted on a substrate, with the substrate being positioned between the conduit section and the converter electronics of the first module. The substrate and converter electronics can be positioned between the energy source of the first module and the conduit section. The system can further include a heat sink positioned between the conduit section and the substrate. The system can further include an interface layer positioned between the conduit section and the heat sink. The interface layer can be deformable. The conduit section can be in contact with the interface layer, which can be in contact with the heat sink, which can be in contact with the substrate. Each of the plurality of modules can have converter electronics mounted on a substrate, with the substrate being positioned between the conduit section and the converter electronics of each module.

[0176] In some embodiments, the enclosure includes a first base section, a second section opposite the base section, and a sidewall section. The conduit section can be in at least one of the first base section, the second section, and the sidewall section. The second section can be a lid of the enclosure, and the conduit section is in the lid.

[0177] In many embodiments, a method of cooling a modular energy system of an electric vehicle is provided, the method including pumping a coolant through a cooling device in proximity to the modular energy system such that the coolant cools modules of the modular energy system, then pumping the coolant in proximity to a motor of the EV to cool the motor, and then pumping the coolant through a heat exchanger to cool the coolant.

[0178] In some embodiments, pumping the coolant through the cooling device includes pumping the coolant in proximity to at least one battery of a module of the modular energy system to cool the at least one battery, and then pumping the coolant in proximity to electronics of the module to cool the electronics.

[0179] In some embodiments, pumping the coolant through the cooling device includes pumping the coolant through a section of the enclosure of the modular energy system, the section being at least one of a base section, a second section opposite the base section, and a sidewall section.

[0180] In some embodiments, pumping the coolant through the cooling device includes pumping the coolant through a base section of the enclosure of the modular energy system and then through a second section of the enclosure opposite the base section. A battery of a module of the modular energy system can be located adjacent to the base section, and electronics of the module of the modular energy system can be located adjacent to the second section. Pumping the coolant through the cooling device can include pumping the coolant through only one of the base section, the second section, and the sidewall section.

[0181] In many embodiments, a modular energy system controllable to supply power to a motor of an electric vehicle is provided, the system including at least three arrays, each array comprising a plurality of modules connected together and outputting an AC voltage signal comprising a superposition of a first output voltage from each module, each module comprising an energy source and converter electronics configured to generate the first output voltage from the energy source, the AC voltage signals output by the three arrays supplying three-phase power to the motor, the energy sources releasably connectable to the converter electronics.

[0182] In some embodiments, the system further includes a latch mechanism configured to releasably connect the energy source to the converter electronics. Each module can include a housing for holding the converter electronics. The housing can be coupled to guide rails for the energy source. The energy source can be slidable along the guide rails.

[0183] In some embodiments, the energy source has a width, a length, and a height, and the length is at least twice the width. The length can be at least three times the width. The length can be at least four times the width.

[0184] In some embodiments, the latching mechanism includes a power connector for connecting an energy source to the converter electronics.

[0185] In some embodiments, the system includes at least one interconnection module including an energy source and a converter, the converter of the interconnection module coupled to at least two of the arrays. The interconnection module can include a housing that holds the converter of the interconnection module, the housing including a control port, at least two connectors for coupling the converter to at least two of the arrays, and at least two connectors for coupling the energy source or the converter of the interconnection module to at least one auxiliary load.

[0186] In some embodiments, the energy source is a battery module, and the housing of each module can include a connector for connecting the battery management system of the battery module to a local control device housed within the housing.

[0187] In some embodiments, the system further includes a control system for controlling the converters of the modules. The control system can be configured to control intra-phase balance within each array. The control system can be configured to control inter-phase balance across the array.

[0188] In many embodiments, an electric vehicle is provided that includes an electric motor, a modular energy system configured according to any of the embodiments described herein to provide power for the electric motor, and at least one access panel configured to move between a first position covering an energy source of the modular energy system and a second position exposing the energy source for removal.

[0189] In some embodiments, the at least one access panel is a door configured to pivot.

[0190] In many embodiments, a method of managing power for an electric vehicle is provided, the electric vehicle including a modular energy system having at least three arrays, each array including a plurality of modules connected together in a cascaded manner to generate an AC voltage signal for a motor of the electric vehicle, each module including a battery module and converter electronics, the method including removing a first battery module from a first location within the electric vehicle and inserting a second battery module into the first location within the electric vehicle, the second battery module having a relatively higher state of charge than the first battery module.

[0191] In some embodiments, removing the first battery module includes unlocking the first battery module from a locked position within the electric vehicle. The method can further include locking a second battery module in the first position.

[0192] In some embodiments, the method further includes moving an access panel of the electric vehicle from a closed position covering the first battery module to an open position exposing the first battery module prior to removing the first battery module. The access panel can be located under the passenger door.

[0193] In some embodiments, the method further includes removing all battery modules from the electric vehicle and inserting different battery modules having a relatively higher state of charge than the removed battery modules.

[0194] In some embodiments, removing the first battery module from the first location within the electric vehicle includes removing the first battery module from electrical contact with first converter electronics associated with the first battery module, and inserting the second battery module into the first location within the electric vehicle includes inserting the second battery module into electrical contact with the first converter electronics.

[0195] In some embodiments, removing the first battery module from the first position within the electric vehicle can include sliding the first battery module along guide rails.

[0196] In some embodiments, inserting the second battery module into the first position within the electric vehicle can include sliding the second battery module along guide rails.

[0197] The term "module," as used herein, refers to one of two or more devices or subsystems within a larger system. A module can be configured to cooperate with other modules of similar size, function, and physical arrangement (e.g., location of electrical terminals, connectors, etc.). Modules with the same function and energy source can be configured the same (e.g., size and physical arrangement) as all other modules in the same system (e.g., rack or pack), while modules with different functions or energy sources may vary in size and physical arrangement. Each module may be physically removable and interchangeable with other modules in the system (e.g., like a wheel on a car or a blade in an information technology (IT) blade server), but this is not required. For example, a system may be packaged in a common housing that does not allow removal and replacement of any one module without disassembly of the system as a whole. However, any embodiment herein can be configured such that each module is removable and replaceable with other modules in a convenient manner without disassembly of the system, etc.

[0198] The term "master control device" is used broadly herein and does not require the implementation of any specific protocol, such as a master and slave relationship with any other device, such as a local control device.

[0199] The term "output" is used broadly herein and does not exclude functioning in a bidirectional manner as both an output and an input. Similarly, the term "input" is used broadly herein and does not exclude functioning in a bidirectional manner as both an input and an output.

[0200] The terms "terminal" and "port" are used broadly herein and can be either unidirectional or bidirectional, can be input or output, and do not require a specific physical or mechanical structure such as a female or male configuration.

[0201] Different reference numeral designations are used herein. These designations are used to facilitate description of the present subject matter and do not limit the scope of the subject matter. Generally, a genus of elements is referred to using a number, e.g., "123," and its subgenera are referred to using a letter appended to the number, e.g., 123A or 123B. A reference to a genus without a letter (e.g., 123) refers to the genus as a whole and includes all subgenera. Some figures show multiple instances of the same element. These elements may be appended with a number or letter in an "-X" format, e.g., 123-1, 123-2, or 123-PA. This -X format does not imply that the elements must be configured identically in each instance, but rather is used to facilitate distinction when referring to elements in the figures. A reference to the genus 123 without the -X designation broadly refers to all instances of the element within the genus.

[0202] Various aspects of the present subject matter are described below with a review of and / or in addition to the previously described embodiments, with emphasis placed on the interrelationships and compatibility of the following embodiments, in other words, the fact that each feature of the embodiments can be combined with any other feature, unless expressly stated otherwise or logically impractical.

[0203] The processing circuitry can include one or more processors, microprocessors, controllers, and / or microcontrollers, each of which can be a discrete or stand-alone chip or distributed among several different chips (and portions thereof). Any type of processing circuitry can be implemented, such as, but not limited to, personal computing architectures (e.g., as used in desktop PCs, laptops, tablets, etc.), programmable gate array architectures, dedicated architectures, custom architectures, and others. The processing circuitry can include digital signal processors, which can be implemented in hardware and / or software. The processing circuitry can execute software instructions stored on memory, which cause the processing circuitry to perform a host of different actions and control other components.

[0204] The processing circuitry may also implement other software and / or hardware routines. For example, the processing circuitry may interface with communications circuitry to perform analog-to-digital conversion, encoding and decoding, other digital signal processing, multimedia functions, conversion of data to a suitable format (e.g., in-phase and quadrature) for presentation to the communications circuitry, and / or cause the communications circuitry to transmit data (wired or wirelessly).

[0205] Any communication signals described herein may be communicated wirelessly unless stated or logically impractical. Communication circuitry may be included for wireless communication. The communication circuitry may be implemented as one or more chips and / or components (e.g., transmitters, receivers, transceivers, and / or other communication circuitry) that implement wireless communication over a link under an appropriate protocol (e.g., Wi-Fi, Bluetooth, Bluetooth Low Energy, near field communication (NFC), radio frequency identification (RFID), proprietary protocols, and others). One or more other antennas may be included with the communication circuitry as needed to operate with various protocols and circuits. In some embodiments, the communication circuitry may share an antenna for transmission over the link. The RF communication circuitry may include a transmitter and receiver (e.g., integrated as a transceiver) and associated encoder logic.

[0206] The processing circuitry may also be adapted to run an operating system and any software applications and to perform their other functions not related to processing transmitted and received communications.

[0207] Computer program instructions for performing operations in accordance with the described subject matter may be written in any combination of one or more programming languages, including object-oriented programming languages ​​such as Java, Java Script, Smalltalk, C++, C#, Transact-SQL, XML, PHP, or the like, and conventional procedural programming languages ​​such as the "C" programming language or similar programming languages.

[0208] The memory, storage, and / or computer-readable medium may be shared by one or more of the various functional units present, or may be distributed among two or more of them (e.g., as separate memories present in different chips). A memory may also reside in its own separate chip.

[0209] To the extent that an embodiment disclosed herein includes or operates in connection with a memory, storage, and / or computer-readable medium, then that memory, storage, and / or computer-readable medium is non-transitory. Thus, to the extent that that memory, storage, and / or computer-readable medium is covered by one or more claims, then that memory, storage, and / or computer-readable medium is only non-transitory. The terms "non-transitory" and "tangible" as used herein are intended to describe memory, storage, and / or computer-readable medium that exclude propagating electromagnetic signals, but are not intended to limit the type of memory, storage, and / or computer-readable medium in terms of persistence of storage or otherwise. For example, "non-transitory" and / or "tangible" memory, storage, and / or computer-readable media encompass volatile and non-volatile media such as random-access media (e.g., RAM, SRAM, DRAM, FRAM, etc.), read-only media (e.g., ROM, PROM, EPROM, EEPROM, Flash, etc.), and combinations thereof (e.g., hybrid RAM and ROM, NVRAM, etc.) and variants thereof.

[0210] It should be noted that all features, elements, components, functions, and steps described with respect to any embodiment provided herein are intended to be freely combinable and substituted with those from any other embodiment. If a feature, element, component, function, or step is described with respect to only one embodiment, it should be understood that that feature, element, component, function, or step can be used in conjunction with all other embodiments described herein unless explicitly stated otherwise. This paragraph therefore serves as a prior basis and written support for the introduction of claims that, at any time, combine features, elements, components, functions, and steps from different embodiments or substitute features, elements, components, functions, and steps from one embodiment with those of another embodiment, even if the following description does not explicitly state that such combinations or substitutions are possible in a particular instance. In particular, it is expressly acknowledged that an explicit description of all possible combinations and substitutions would be overly burdensome, given that the permissibility of all such combinations and substitutions would be readily recognized by one skilled in the art.

[0211] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0212] While the embodiments are susceptible to various modifications and alternative forms, specific examples thereof have been shown in the drawings and are described in detail herein. It should be understood, however, that these embodiments are not limited to the particular forms disclosed, but on the contrary, these embodiments are intended to cover all modifications, equivalents, and alternatives falling within the spirit of the disclosure. Furthermore, negative limitations may be set forth in or added to the claims that define the scope of any feature, function, step, or element of the embodiments, as well as any feature, function, step, or element not within the scope of the claimed invention.

Claims

1. 1. A modular energy system controllable to supply electrical power to a load, the system comprising: a plurality of modules connected together to output an AC voltage signal, the AC voltage signal being formed by a superposition of first output voltages from each module, each module comprising an energy source and converter electronics connected to the energy source, the converter electronics configured to generate the first output voltage from the energy source; an enclosure for the plurality of modules, the enclosure configured to pass a coolant therethrough to cool the plurality of modules, the enclosure including a conduit section configured to pass the coolant therethrough; Equipped with a first module of the plurality of modules having first converter electronics mounted on a first substrate within a first electronics enclosure of the first module, the first substrate being positioned between the conduit section and the first converter electronics of the first module; a second module of the plurality of modules having second converter electronics mounted on a second board within a second electronics enclosure of the second module, the second board being positioned between the conduit section and the second converter electronics of the second module; The system further comprises a first heat sink positioned between the conduit section and the first substrate.

2. The system of claim 1 , wherein the enclosure comprises a channel having a shape corresponding to a shape of the conduit segment, the conduit segment being positioned within the channel.

3. The system of claim 2 , wherein the conduit section is an interference fit within the channel.

4. The system of claim 1 , wherein the first board and first converter electronics are positioned between a first energy source of the first module and the conduit section.

5. The system of claim 1 , further comprising an interface layer positioned between the conduit section and the first heat sink.

6. The system of claim 5 , wherein the interface layer is deformable.

7. The system of claim 5 , wherein the conduit section contacts the interface layer, the interface layer contacts the first heat sink, and the first heat sink contacts the first substrate.

8. 2. The system of claim 1, wherein each of the plurality of modules has associated converter electronics mounted on an associated board, the associated board of each module being positioned between the conduit section and the associated converter electronics of the module.

9. The system of claim 1 , wherein the enclosure comprises a first base section, a second section opposite the base section, and a sidewall section.

10. The system of claim 9 , wherein the conduit section is within at least one of the first base section, the second section, and the sidewall section.

11. The system of claim 10 , wherein the second section is a lid of the enclosure and the conduit section is within the lid.

12. The system of claim 1 , wherein the first energy source comprises a fuel cell, a battery module, or a capacitor.

13. The system of claim 1 , wherein the enclosure comprises a top enclosure and a bottom enclosure, and the conduit section is located within the top enclosure of the enclosure.

14. 14. The system of claim 13, wherein the bottom enclosure of the enclosure also includes the conduit section, the conduit section fluidly coupling the top enclosure of the enclosure and the bottom enclosure of the enclosure.

15. 15. The system of claim 14, wherein the first heat sink is positioned between a first conduit section in the upper enclosure of the enclosure and the first substrate.

16. 15. The system of claim 14, wherein the first heat sink is positioned between the conduit section and the first substrate within the bottom enclosure of the enclosure.

17. 1. A method comprising: connecting first converter electronics mounted on a first side of a first substrate within a first electronics enclosure of a first module to a first energy source such that the first converter electronics is between the first energy source and the first substrate to form the first module; positioning a first heat sink on a second side of the first substrate opposite the first side of the first substrate; connecting second converter electronics mounted on a first side of a second substrate within a second electronics enclosure of a second module to a second energy source such that the second converter electronics is between the second energy source and the second substrate to form the second module; positioning a second heat sink on a second side of the second substrate opposite the first side of the second substrate; placing the first module and the second module in an enclosure configured to pass a coolant through the enclosure to cool the first module and the second module, the enclosure including a conduit section configured to pass the coolant; Including, The first module comprises: the first heat sink is positioned between the conduit section and the first substrate; the first substrate is positioned between the first heat sink and the first converter electronics; The first converter electronics of the first module are between the first substrate and the first energy source. and wherein the enclosure is disposed such that

18. The method of claim 17 , further comprising positioning the conduit section within a channel of the enclosure, the channel corresponding to a shape of the conduit section.

19. The method of claim 18 , wherein positioning the conduit section within the channel comprises interference-fitting the conduit section within the channel.

20. The method of claim 17 , wherein the first energy source comprises a fuel cell, a battery module, or a capacitor.

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