Energy systems for managing power to primary and auxiliary loads

Abstract

Energy systems for managing power to primary and auxiliary loads are provided. One example energy system includes a primary and an auxiliary subsystem coupled to each other by a primary converter. The primary subsystem is a module-based energy system that includes modules arranged in cascaded fashion for generating AC power. Each module includes an energy source and a converter that selectively couples the energy source to other modules in the primary subsystem. The primary subsystem can be arranged in single-phase or multiphase topologies. The auxiliary subsystem includes one or more energy sources connected together for generating DC power. The primary converter can convert AC-to-DC power for managing power demands between the primary and auxiliary sides of the energy system. A charge source or intermittently available charge sources for performing multiphase AC, single-phase AC, DC, or DC pulse charging of the energy system are also described.

Description

ENERGY SYSTEMS FOR MANAGING POWER TO PRIMARY AND AUXILIARY LOADSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is an International Application which claims priority to U.S. Provisional Patent Application No. 63 / 539,318, filed September 19, 2023. The disclosure of the foregoing application is hereby incorporated by reference in its entirety and for all purposes.FIELD

[0002] The subject matter described herein relates generally to energy systems for managing power to primary and auxiliary loads, as well as systems, devices, and methods for charging energy sources of the energy systems.BACKGROUND

[0003] Energy systems having multiple energy sources or sinks are commonplace in many industries. One example is the automotive industry. Today’s automotive technology, as evolved over the past century, is characterized, amongst many things, by an interplay of motors, mechanical elements, and electronics. These are the key components that impact vehicle performance and driver experience. Motors are of the combustion or electric type and in almost all cases the rotational energy from the motor is delivered via a set of highly sophisticated mechanical elements, such as clutches, transmissions, differentials, drive shafts, torque tubes, couplers, etc. These parts control, to a large degree, torque conversion and power distribution to the wheels which govern the performance of the vehicle and road handling.

[0004] An electric vehicle (EV) includes various electrical systems that are related to the drivetrain including, among others, the battery pack, the charger, and motor control. High- voltage battery packs are typically organized in a serial chain of lower voltage battery modules. Each such battery module further includes a set of serially connected individual cells and an embedded Battery Management System (BMS) to regulate basic cell-related characteristics, such as state of charge and voltage. Electronics with more sophisticated capabilities or some form of smart interconnectedness are absent. As a consequence, any monitoring or control function is handled by a separate system, which, if at all present elsewhere in the car, lacks the ability to monitor individual cell health, state of charge, temperature, and other performance-impacting metrics. There is also no ability tomeaningfully adjust the power draw per individual cell in any form. Some of the major consequences are: (1) the weakest cell constrains the overall performance of the entire battery pack, (2) failure of any cell or battery module leads to a need for replacement of the entire pack, (3) battery reliability and safety are considerably reduced, (4) battery life is limited, (5) thermal management is difficult, (6) battery packs always operate below maximum capabilities, and (7) sudden inrush of regenerative braking derived electric power cannot be readily stored in the batteries and requires dissipation via a dump resistor.

[0005] Conventional controls contain DC-to-DC conversion stages to adjust battery pack voltage levels to the bus voltage of the EV’s electrical system. Motors, in turn, are then driven by simple two-level multiphase standalone drive inverters that provide the required AC signal(s) to the electric motor. Each motor is traditionally controlled by a separate controller, which drives the motor in a three-phase design. Dual motor EVs would require two controllers, while EVs using four in-wheel motors would require four individual controllers. The conventional controller design also lacks the ability to drive next-generation motors, such as switch reluctance motors (SRM), characterized by higher numbers of pole pieces. Adaptation would generally involve higher phase designs, making the systems more complex and ultimately failing to address electric noise and driving performance, such as high torque ripple and acoustical noise.

[0006] Many of these deficiencies apply not only to automobiles but other motor-driven vehicles, as well as to stationary applications to a significant extent. For these and other reasons, needs exist for improved energy systems, particularly module-based cascaded energy systems, that can efficiently manage power for mobile and stationary applications.SUMMARY

[0007] Example embodiments of energy systems are provided herein for managing power to primary and auxiliary loads (e.g., loads of an EV), as well as systems, devices, and methods for charging energy sources of the energy systems. The energy systems include a primary subsystem and an auxiliary subsystem that are coupled to each other by way of one or more power converters, including a primary converter. The energy systems provide robust power management to multiple loads having different voltage, current, and / or power demands.

[0008] The primary subsystem is a module-based energy system that includes multiple modules arranged in a cascaded fashion. Each module includes an energy source and a converter that selectively couples the energy source to other modules in the primarysubsystem for generating AC power for an AC bus, or for receiving and storing power from a charge source via the AC bus. A primary load can be coupled to the AC bus to receive AC power. The primary subsystem can be arranged in single-phase or multiphase topologies with one or more serial or interconnected arrays. In some embodiments, the primary subsystem can be implemented as a module-based battery pack that includes multiple connected modules having battery modules as energy sources.

[0009] The auxiliary subsystem includes one or more energy sources connected together for generating DC power for a DC bus, or for receiving and storing power generated from the primary subsystem and / or the charge source via the DC bus. An auxiliary load (e.g., a high- voltage auxiliary load) can be coupled to the DC bus to receive DC power. In some embodiments, the auxiliary subsystem can be implemented as a conventional (e.g., high- voltage) battery pack that includes one or more connected battery modules as energy sources.

[0010] The primary converter is coupled between the AC bus and the DC bus. The primary converter is configured to convert AC power to DC power for managing power demands between the primary (AC) and auxiliary (DC) sides of the energy system. For example, the primary converter can convert AC power generated by the primary subsystem to charge the auxiliary subsystem and / or provide supplemental DC power for the auxiliary load. In some embodiments, the primary converter can be implemented as a unidirectional converter that isolates the auxiliary subsystem from the primary load. In other embodiments, the primary converter can be implemented as a bidirectional converter that converts DC power generated by the auxiliary subsystem for charging the primary subsystem and / or providing supplemental power to the primary load.

[0011] The energy systems can be configured with bidirectional charging and discharging capability through one or more charge ports. Routing circuitry can selectively route current from a charge port to the primary and auxiliary subsystems based on the type of charge signals applied, such as DC, single-phase AC, and multiphase AC charge signals. The routing circuitry can include solid-state relays (SSRs) that isolate the energy systems from the external charge source. The energy systems can also utilize DC pulse charging when receiving a DC charge signal. For example, the primary subsystem can cycle converters of each of its modules, or the routing circuitry can appropriately switch to shape the DC charge signal into a particular pulsed (e.g., square) waveform.

[0012] Example embodiments of switching assemblies are also provided. The switching assemblies, in some embodiments referred to as a power and control distribution assembly(PCDA), can act as a centralized hub for power and control connections for an energy system, as well as all or a portion of an EV. The switching assemblies can include portions of the energy system’s control system and routing circuitry related to a charge network distributor.

[0013] The energy systems can also be configured for charging from an intermittently connected charge source. For example, in some embodiments, each module of the primary subsystem includes multiple (e.g., two) converters such that the module can receive relatively high-voltage charge signals from the intermittently connected charge source and modify that charge signal with one of the converters to charge the energy source of the module. Each module can utilize another one of the converters to convert the DC output voltage from the energy source into an AC output voltage. The energy systems can also include an auxiliary converter to utilize charge signals from the intermittently available charge source for charging the auxiliary subsystem directly. For mobile applications such as EVs, the charging can occur while the EV is moving, such as with a rail-based EV receiving power from an overhead, ground-level, or below-ground charge source.

[0014] The energy systems disclosed herein can have numerous different topologies that can include one or more primary subsystems and one or more auxiliary subsystems coupled together by one or more primary converters for converting between AC and DC power supplied by the subsystems. The energy systems can be configured to supply power for one or more primary loads and one or more auxiliary loads. In some embodiments, the primary and auxiliary subsystems are also coupled by one or more auxiliary converters for converting between various forms of DC power. For example, an auxiliary subsystem can be coupled to energy sources of interconnection modules of a primary subsystem and / or DC lines of the energy systems using an auxiliary (e.g., DC-DC) converter.

[0015] The energy systems can be utilized for stationary and mobile applications. For stationary applications, a primary load may include an electrical grid coupled to the AC bus. For mobile applications such as an EV, a primary load may include one or more motors (e.g., three-phase motors) of the EV coupled to the AC bus. An auxiliary load can include one or more high-voltage (HV) auxiliary loads and / or one or more low-voltage (LV) auxiliary loads coupled to the DC bus. As one example, in the context of an EV, a HV auxiliary load may include an HVAC system or an onboard electrical system of the EV. In a similar vein, a LV auxiliary load may include a display of the EV or a personal electronic device for a passenger of the EV. The HV and LV auxiliary loads may each be coupled to the DC bus via respectiveconverters for boosting, bucking, and / or performing DC-to-AC conversion to meet their respective voltage, current, and / or power demands. For example, the one or more HV auxiliary loads may each be coupled to the DC bus via a respective DC-AC converter for high-voltage conversion, and the one or more LV auxiliary loads may each be coupled to the DC bus via a respective DC-DC converter for buck conversion. In some embodiments, such power converters, including any primary and auxiliary converters of an energy system, can be integrated into the PCDA to provide a centralized power management and conversion unit.

[0016] The energy systems can be implemented in one or more enclosures associated with one or more thermal management systems. The thermal management systems can circulate a heat transfer fluid in proximity with components (e.g., energy sources and / or electronics) of the primary and auxiliary subsystems of an energy system. The thermal management systems can utilize various configurations such as a network of conduits or bladders to conduct the heat transfer fluid in proximity to these components. Further, the thermal management systems can be reconfigurable to cool and / or heat the energy sources of each subsystem, as well as provide heating or cooling to a particular space, e.g., a passenger compartment of an EV. The thermal management systems can also be reconfigured to utilize different heat exchangers based on a variety of factors, such as exterior temperature, temperature of modules, temperature of associated electronics, temperature of energy sources, and / or temperature of coolant within an air conditioning (AC) or heat pump (HP) system.

[0017] Example embodiments of module layouts are also provided. The module layouts can include some or all of a module’s electronics placed in an inverted orientation to maximize surface area contact of an electronics substrate with a heatsink of the module (or a bladder in some embodiments). Variations in the placement of connectors for primary ports, auxiliary ports, and control ports are also described.

[0018] Example embodiments of energy system layouts for an EV (e.g., an electric bus) are also provided. The energy systems can include one or more primary subsystems and one or more auxiliary subsystems for providing AC and DC power to various loads of the EV at a desired voltage and / or power rating. Each subsystem can be housed in a respective enclosure associated with a respective thermal management system and positioned on a top and / or bottom portion of the EV.

[0019] Other systems, devices, methods, features, and advantages of the subject matter described herein will be apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems,methods, features, and advantages be included within this description, and be within the scope of the subject matter described herein. In no way should the features of the example embodiments be construed as limiting the appended claims, absent express recitation of those features in the claims.BRIEF DESCRIPTION OF FIGURES

[0020] The details of the subject matter set forth herein, both as to its structure and operation, may be apparent by study of the accompanying figures, in which like reference numerals refer to like parts. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the subject matter. Moreover, all illustrations are intended to convey concepts, where relative sizes, shapes, and other detailed attributes may be illustrated schematically rather than literally or precisely.

[0021] FIGs. 1 A-1C are block diagrams depicting example embodiments of a modular energy system.

[0022] FIGs. 1D-1E are block diagrams depicting example embodiments of control devices for an energy system.

[0023] FIGs. 1F-1G are block diagrams depicting example embodiments of modular energy systems coupled with a load and a charge source.

[0024] FIGs. 2A-2B are block diagrams depicting example embodiments of a module and control system within an energy system.

[0025] FIG. 2C is a block diagram depicting an example embodiment of a physical configuration of a module.

[0026] FIG. 2D is a block diagram depicting an example embodiment of a physical configuration of a modular energy system.

[0027] FIGs. 3A-3C are block diagrams depicting example embodiments of modules having various electrical configurations.

[0028] FIGs. 4A-4F are schematic diagrams depicting example embodiments of energy sources.

[0029] FIGs. 5A-5K are schematic diagrams depicting example embodiments of energy buffers.

[0030] FIGs. 5L-5N are schematic diagrams depicting example embodiments of switch units that can be utilized for actively controlled energy buffers.

[0031] FIGs. 6A-6C are schematic views depicting example embodiments of converters.

[0032] FIGs. 7A-7E are block diagrams depicting example embodiments of modular energy systems having various topologies.

[0033] FIG. 8A is a plot depicting an example output voltage of a module.

[0034] FIG. 8B is a plot depicting an example multilevel output voltage of an array of modules.

[0035] FIG. 8C is a plot depicting an example reference signal and carrier signals usable in a pulse width modulation control technique.

[0036] FIG. 8D is a plot depicting example reference signals and carrier signals usable in a pulse width modulation control technique.

[0037] FIG. 8E is a plot depicting example switch signals generated according to a pulse width modulation control technique.

[0038] FIG. 8F is a plot depicting an example multilevel output voltage generated by the superposition of output voltages from an array of modules under a pulse width modulation control technique.

[0039] FIGs. 9A and 9B are block diagrams depicting example embodiments of controllers for a modular energy system.

[0040] FIG. 10A is a block diagram depicting an example embodiment of a multiphase modular energy system having an interconnection module.

[0041] FIG. 10B is a schematic diagram depicting an example embodiment of an interconnection module in the multiphase embodiment of FIG. 10 A.

[0042] FIG. 10C is a block diagram depicting an example embodiment of a modular energy system having two subsystems connected together by interconnection modules.

[0043] FIG. 10D is a block diagram depicting an example embodiment of a three-phase modular energy system having interconnection modules supplying auxiliary loads.

[0044] FIG. 10E is a schematic view depicting an example embodiment of the interconnection modules in the multiphase embodiment of FIG. 10D.

[0045] FIG. 1 OF is a block diagram depicting another example embodiment of a three- phase modular energy system having interconnection modules supplying auxiliary loads.

[0046] FIGs. 11 A-l IB are block diagrams depicting example embodiments of an energy system configured for multiphase charging.

[0047] FIG. 11C is a flow diagram depicting an example process for charging an energy system.

[0048] FIG. 1 ID is a plot depicting an example of a three-phase charging signal.

[0049] FIGs. 1 IE-11G are block diagrams depicting example embodiments of an auxiliary subsystem of an energy system.

[0050] FIGs. 11H-1 IL are schematic diagrams depicting example embodiments of a primary converter configured for AC-to-DC conversion.

[0051] FIGs. 1 IM-1 IN are schematic diagrams depicting example embodiments of an auxiliary converter configured for DC-to-DC conversion.

[0052] FIG. 12A is a block diagram depicting an example embodiment of an energy system configured for DC and AC charging.

[0053] FIG. 12B is a schematic diagram depicting an example embodiment of routing circuitry.

[0054] FIGs. 12C-12E are schematic diagrams depicting example embodiments of solid- state relays for use in routing circuitry.

[0055] FIG. 12F is a block diagram depicting an example embodiment of an energy system configured for DC, single-phase AC, and multiphase AC charging.

[0056] FIG. 12G is a schematic diagram depicting another example embodiment of routing circuitry.

[0057] FIG. 12H is a schematic diagram depicting the example embodiment of routing circuitry in FIG. 12B configured with an energy buffer.

[0058] FIGs. 13A-13B are block diagrams depicting example embodiments of an energy system configured for DC, single-phase AC, and multiphase AC charging.

[0059] FIG. 13C is a schematic diagram depicting another example embodiment of routing circuitry.

[0060] FIG. 13D is a block diagram depicting an example embodiment of an energy system configured for DC, single-phase AC, and multiphase AC charging.

[0061] FIG. 14 is a block diagram depicting an example embodiment of an energy system configured for DC and / or single-phase AC charging through a motor, and multiphase charging bypassing the motor.

[0062] FIGs. 15A-15B are block diagrams depicting example embodiments of an energy system in a delta and series arrangement configured for DC, single-phase AC, and multiphase charging.

[0063] FIGs. 16A-16B are block diagrams depicting example embodiments of energy systems configured for DC, single-phase AC, and multiphase AC charging.

[0064] FIG. 16C is a block diagram depicting an example embodiment of a primary subsystem that can be implemented in the energy systems of FIGs. 16A-16B.

[0065] FIG. 17 is a block diagram depicting an example embodiment of an energy system configured for intermittent charging.

[0066] FIGs. 18A-18B are block diagrams depicting example embodiments of modules for use in an energy system configured for intermittent charging.

[0067] FIGs. 19A-19C are schematic diagrams depicting example embodiments of modules for use in an energy system configured for intermittent charging.

[0068] FIGs. 20A-20B are block diagrams depicting example embodiments of primary subsystem topologies for intermittent charging.

[0069] FIGs. 20C-20D are schematic diagrams depicting example embodiments of interconnection modules for use in an energy system configured for intermittent charging.

[0070] FIG. 21 A is a block diagram depicting an example embodiment of a power and control distribution assembly interfacing with an energy system.

[0071] FIG. 2 IB is a schematic diagram depicting an example embodiment of a power and control distribution assembly interfacing with an energy system configured for an electric vehicle.

[0072] FIG. 21C is a perspective view depicting an example embodiment of a power and control distribution assembly interfacing with an energy system configured for an electric vehicle.

[0073] FIGs. 21D-21E are perspective views of an exterior and interior, respectively, of an example embodiment of a power and control distribution assembly.

[0074] FIG. 2 IF as an exploded view depicting an example embodiment of the power and control distribution assembly in FIGs. 21D-21E.

[0075] FIG. 21G is a perspective view of an example embodiment of a charge network distributor within an electric vehicle.

[0076] FIG. 22A is a block diagram depicting an example embodiment of a process flow for cooling components of an electric vehicle.

[0077] FIG. 22B is a perspective view depicting an example embodiment of an enclosure configured for cooling subsystems of an energy system.

[0078] FIG. 22C is a perspective view depicting an example embodiment of an enclosure having a top and bottom enclosure each configured with a network of conduits.

[0079] FIG. 22D is a perspective view depicting an example embodiment of an enclosure having a top and bottom enclosure each configured with a network of bladders.

[0080] FIG. 22E is a cross-sectional view depicting an example embodiment of a module in proximity with a thermal management system utilizing two networks of conduits for cooling.

[0081] FIG. 22F is a cross-sectional view depicting an example embodiment of a module in proximity with a thermal management system utilizing two networks of bladders for cooling.

[0082] FIG. 23 A is a block diagram depicting another example embodiment of a process flow for cooling components of an electric vehicle.

[0083] FIG. 23B is a perspective view depicting another example embodiment of an enclosure configured for cooling subsystems of an energy system.

[0084] FIG. 23C is a perspective view depicting an example embodiment of an enclosure having a top enclosure configured with a network of conduits.

[0085] FIG. 23D is a perspective view depicting an example embodiment of an enclosure having a top enclosure configured with a network of bladders.

[0086] FIG. 23E is a cross-sectional view depicting an example embodiment of a module in proximity with a thermal management system utilizing a network of conduits for cooling.

[0087] FIG. 23F is a cross-sectional view depicting an example embodiment of a module in proximity to a thermal management system utilizing a network of bladders for cooling.

[0088] FIGs. 23G-23H are perspective views depicting another example embodiment of an enclosure having an intermediate panel configured for cooling subsystems of an energy system.

[0089] FIG. 231 is a perspective view depicting an example embodiment of an intermediate panel configured with a network of conduits.

[0090] FIG. 23 J is a perspective view depicting an example embodiment of an intermediate panel configured with a network of bladders.

[0091] FIG. 23K is a cross-sectional view depicting an example embodiment of a module having a battery module and electronics in proximity with a thermal management system utilizing a network of conduits for cooling.

[0092] FIG. 23L is a cross-sectional view depicting an example embodiment of a module having a battery module and electronics in proximity with a thermal management system utilizing a network of bladders for cooling.

[0093] FIGs. 24A-24D are block diagrams depicting example embodiments of thermal management systems.

[0094] FIGs. 24E-24G are perspective views depicting an example embodiment of an enclosure having a primary subsystem, a local power distribution unit, and a thermal management system housed therein.

[0095] FIGs. 24H-24J are block diagrams depicting additional example embodiments of thermal management systems.

[0096] FIG. 25A is an exploded view depicting an example embodiment of a module.

[0097] FIGs. 25B-25C are perspective views depicting an exterior and interior, respectively, of an example embodiment of a module.

[0098] FIG. 25D is a cross-sectional view depicting an example embodiment of electronics of a module.

[0099] FIGs. 25E-25F are top-down views depicting example embodiments of modules connected within an array.

[0100] FIGs. 25G-25H are top-down views depicting example embodiments of cells within a battery module.

[0101] FIGs. 25I-25L are top-down views depicting example embodiments of modules.

[0102] FIGs. 26A-26B are perspective views depicting an example embodiment of an energy system arranged on or within an electric vehicle.

[0103] FIGs. 26C-26D are perspective views depicting other example embodiments of energy systems arranged on or within an electric vehicle.DETAILED DESCRIPTION

[0104] Before the present subject matter is described in detail, it is to be understood that this disclosure is not limited to the particular embodiments described, as such may, of course, vary. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting, since the scope of the present disclosure will be limited only by the appended claims.

[0105] Before describing the example embodiments pertaining to energy systems utilizing various modular subsystems for power management, it is first useful to describe these underlying modular energy systems in greater detail. With reference to FIGs. 1A-10F,the following Sections 1-7 describe various applications in which embodiments of the modular energy systems can be implemented, embodiments of control systems or devices for the modular energy systems, configurations of the modular energy system embodiments with respect to charge sources and loads, embodiments of individual modules, embodiments of topologies for arrangement of the modules within the systems, embodiments of control methodologies, embodiments for balancing operating characteristics of modules within the systems, embodiments with the use of interconnection modules, and embodiments of energy sources with first and / or second life applications.

[0106] Hence, for ease of description, this specification is organized as follows. Sections 1-7 describe modular energy systems as noted above. Sections 8-22 describe various aspects of energy systems utilizing primary and auxiliary subsystems for power management, where a primary subsystem is configured as a modular energy system for generating AC power, and an auxiliary subsystem is configured as a non-modular energy system for generating DC power. Sections 8-16 describe embodiments of the energy systems for single-phase AC, multiphase AC, DC, and DC pulse charging. Section 17 describes embodiments of the energy systems for intermittent charging. Sections 19-20 describe embodiments of power and control distribution assemblies (PCD As) and charge network distributors (CNDs) to manage charging, power generation, and control signals to and from the energy systems. Section 20 describes embodiments of thermal management systems for the energy systems. Section 21 describes additional embodiments for module layouts of the energy systems. Section 22 describes embodiments of the energy systems arranged on or within an electric vehicle (EV).Section 1: Examples of Applications

[0107] Stationary applications are those in which the modular energy system is located in a fixed location during use, although it may be capable of being transported to alternative locations when not in use. The module-based energy system resides in a static location while providing electrical energy for consumption by one or more other entities, or storing or buffering energy for later consumption. Examples of stationary applications in which the embodiments disclosed herein can be used include, but are not limited to: energy systems for use by or within one or more residential structures or locales, energy systems for use by or within one or more industrial structures or locales, energy systems for use by or within one or more commercial structures or locales, energy systems for use by or within one or more governmental structures or locales (including both military and non-military uses), energy systems for charging the mobile applications described below (e.g., a charge source or acharging station), and systems that convert solar power, wind, 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. A stationary energy system can be used in either a storage or non-storage role.

[0108] Mobile applications, sometimes referred to as traction applications, are generally ones where a module-based energy system is located on or within an entity, and stores and provides electrical energy for conversion into motive force by a motor to move or assist in moving that entity. Examples of mobile entities with which the embodiments disclosed herein can be used include, but are not limited to, electric and / or hybrid entities that move over or under land, over or undersea, above and out of contact with land or sea (e.g., flying or hovering in the air), or through outer space. Examples of mobile entities with which the embodiments disclosed herein can be used include, but are not limited to, vehicles, trains, trams, ships, vessels, aircraft, and spacecraft. Examples of mobile vehicles with which the embodiments disclosed herein can be used include, but are not limited to, those having only one wheel or track, those having only two wheels or tracks, those having only three wheels or tracks, those having only four wheels or tracks, and those having five or more wheels or tracks. Examples of mobile entities with which the embodiments disclosed herein can be used include, but are not limited to, a car, a bus, a truck, a motorcycle, a scooter, an industrial vehicle, a mining vehicle, a flying vehicle (e.g., a plane, a helicopter, a drone, etc.), a maritime vessel (e.g., commercial shipping vessels, ships, yachts, boats or other watercraft), a submarine, a locomotive or rail-based vehicle (e.g., a train, a tram, etc.), a military vehicle, a spacecraft, and a satellite.

[0109] In describing embodiments herein, reference may be made to a particular stationary application (e.g., grid, micro-grid, data centers, cloud computing environments) or mobile application (e.g., an electric car). Such references are made for ease of explanation and do not mean that a particular embodiment is limited for use to only that particular mobile or stationary application. Embodiments of systems providing power to a motor can be used in both mobile and stationary applications. While certain configurations may be more suitable to some applications over others, all example embodiments disclosed herein are capable of use in both mobile and stationary applications unless otherwise noted.Section 2: Module-based Energy System Examples

[0110] FIG. 1 A is a block diagram depicting an example embodiment of a module-based energy system 100. Here, system 100 includes a control system 102 communicativelycoupled with N converter- source modules 108-1 through 108-N, over communication paths or links 106-1 through 106-N, respectively. Modules 108 are configured to store energy and output the energy as needed to a load 101 (or other modules 108). In these embodiments, any number of two or more modules 108 can be used (e.g., N is greater than or equal to two). Modules 108 can be connected to each other in a variety of manners as will be described in more detail with respect to FIGs. 7A-7E. For ease of illustration, in FIGs. 1 A-1C, modules 108 are shown connected in series, or as a one-dimensional array, where the Nth module is coupled to load 101.

[0111] 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 charge source. FIG. IF is a block diagram depicting an example embodiment of system 100 with a power input interface 151 for receiving power from a charge source 150 and a power output interface 152 for outputting power to load 101. In this embodiment, system 100 can receive and store power over interface 151 at the same time as outputting power over interface 152. FIG. 1G is a block diagram depicting another example embodiment of system 100 with a switchable interface 154. In this embodiment, system 100 can select, or be instructed to select, between receiving power from charge source 150 and outputting power to load 101. System 100 can be configured to supply multiple loads 101, including both primary and auxiliary loads, and / or receive power from multiple charge sources 150, e.g., a utility- operated power grid and a local renewable energy source (e.g., solar).

[0112] FIG. IB depicts another example embodiment of system 100. Here, control system 102 is implemented as a main control device (MCD) 112 communicatively coupled with N different local control devices (LCDs) 114-1 through 114-N over communication paths or links 115-1 through 115-N, respectively. Each LCD 114-1 through 114-N is communicatively coupled with one module 108-1 through 108-N over communication paths or links 116-1 through 116-N, respectively, such that there is a 1 : 1 relationship between LCDs 114 and modules 108.

[0113] FIG. 1C depicts another example embodiment of system 100. Here, MCD 112 is communicatively coupled with M different LCDs 114-1 to 114-M over communication paths or links 115-1 to 115-M, respectively. Each LCD 114 can be coupled with and control two or more modules 108. In the example shown here, each LCD 114 is communicatively coupled with two modules 108, such that M LCDs 114-1 through 114-M are coupled with 2Mmodules 108-1 through 108-2M over communication paths or links 116-1 to 116-2M, respectively.

[0114] Control system 102 can be configured as a single device (e.g., FIG. 1 A) for the entire system 100 or can be distributed across or implemented as multiple devices (e.g., MCD 112 and LCDs 114 as shown in FIGs. 1B-1C). In some embodiments, control system 102 can be distributed between LCDs 114 associated with the modules 108, such that no MCD 112 is necessary and can be omitted from system 100.

[0115] Control system 102 can be configured to execute control using software (instructions stored in memory that are executable by processing circuitry), hardware, or a combination thereof. The one or more devices of control system 102 can each include processing circuitry 120 and memory 122 as shown here. Example implementations of processing circuitry and memory are described further below.

[0116] Control system 102 can have a communicative interface for communicating with devices 104 external to system 100 over a communication link or path 105. For example, control system 102 (e.g., MCD 112) can output data or information about system 100 to another control device 104 (e.g., the Electronic Control Unit (ECU) or Motor Control Unit (MCU) of a vehicle in a mobile application, grid controller in a stationary application, etc.).

[0117] Communication links or paths 105, 106, 115, 116, and 118 (FIG. 2B) can each be wired (e.g., electrical, optical) or wireless communication paths that communicate data or information bidirectionally, in parallel or series fashion. Data can be communicated in a standardized (e.g., IEEE, ANSI) or custom (e.g., proprietary) format. In automotive applications, communication paths 115 can be configured to communicate according to FlexRay or CAN protocols. Communication paths 106, 115, 116, and 118 can also provide wired power to directly supply the operating power for control system 102 from one or more modules 108. For example, the operating power for each LCD 114 can be supplied only by the one or more modules 108 to which that LCD 114 is connected and the operating power for MCD 112 can be supplied indirectly from one or more of modules 108 (e.g., such as through a car’s power network).

[0118] 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 modules 108. Control can also be based on one or more other factors, such as energy requirements of 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.

[0119] Status information of every module 108 in system 100 can be communicated to control system 102, which can independently control every module 108-1 through 108-N. Other variations are possible. For example, a particular module 108 (or subset of modules 108) can be controlled based on status information of that particular module 108 (or subset), based on status information of a different module 108 that is not that particular module 108 (or subset), based on status information of all modules 108 other than that particular module 108 (or subset), based on status information of that particular module 108 (or subset) and status information of at least one other module 108 that is not that particular module 108 (or subset), or based on status information of all modules 108 in system 100.

[0120] 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 components thereof (e.g., energy source, energy buffer, converter, monitor circuitry): State of Charge (SOC) (e.g., the level of charge of an energy source relative to its capacity, such as a fraction or percent) of the one or more energy sources of the module, State of Health (SOH) (e.g., a figure of merit of the condition of an energy source compared to its ideal conditions) of the one or more energy sources of the module, temperature of the one or more energy sources or other components of the module, capacity of the one or more energy sources of the module, voltage of the one or more energy sources and / or other components of the module, current of the one or more energy sources and / or other components of the module, State of Power (SOP) (e.g., the available power limitation of the energy source during discharge and / or charge), State of Energy (SOE) (e.g., the present level of available energy of an energy source relative to the maximum available energy of the source), and / or the presence of absence of a fault in any one or more of the components of the module.

[0121] LCDs 114 can be configured to receive the status information from each module 108, or determine the status information from monitored signals or data received from or within each module 108, and communicate that information to MCD 112. In some embodiments, each LCD 114 can communicate raw collected data to MCD 112, which then algorithmically determines the status information on the basis of that raw data. MCD 112 can then use the status information of modules 108 to make control determinations accordingly. The determinations may take the form of instructions, commands, or other information (such as a modulation index described herein) that can be utilized by LCDs 114 to either maintain or adjust the operation of each module 108.

[0122] For example, MCD 112 may receive status information and assess that information to determine a difference between at least one module 108 (e.g., a component thereof) and at least one or more other modules 108 (e.g., comparable components thereof). For example, MCD 112 may determine that a particular module 108 is operating with one of the following conditions as compared to one or more other modules 108: with a relatively lower or higher SOC, with a relatively lower or higher SOH, with a relatively lower or higher capacity, with a relatively lower or higher voltage, with a relatively lower or higher current, with a relatively lower or higher temperature, or with or without a fault. In such examples, MCD 112 can output control information that causes the relevant aspect (e.g., output voltage, current, power, temperature) of that particular module 108 to be reduced or increased (depending on the condition). In this manner, the utilization of an outlier module 108 (e.g., operating with a relatively lower SOC or higher temperature), can be reduced to cause the relevant parameter of that module 108 (e.g., SOC or temperature) to converge towards that of one or more other modules 108.

[0123] The determination of whether to adjust the operation of a particular module 108 can be made by comparison of the status information to predetermined thresholds, limits, or conditions, and not necessarily by comparison to statuses of other modules 108. The predetermined thresholds, limits, or conditions can be static thresholds, limits, or conditions, such as those set by the manufacturer that do not change during use. The predetermined thresholds, limits, or conditions can be dynamic thresholds, limits, or conditions, that are permitted to change, or that do change, during use. For example, MCD 112 can adjust the operation of a module 108 if the status information for that module 108 indicates it to be operating in violation (e.g., above or below) of a predetermined threshold or limit, or outside of a predetermined range of acceptable operating conditions. Similarly, 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 indicates the absence or removal of an actual or potential fault. Examples of a fault include, but are not limited to, an actual failure of a component, a potential failure of a component, a short circuit or other excessive current condition, an open circuit, an excessive voltage condition, a failure to receive a communication, the receipt of corrupted data, and the like. Depending on the type and severity of the fault, the faulty module’s utilization can be decreased to avoid damaging the module, or the module’s utilization can be ceased altogether. For example, if a faultoccurs in a given module, then MCD 112 or LCD 114 can cause that module to enter a bypass state as described herein.

[0124] MCD 112 can control modules 108 within system 100 to achieve or converge towards a desired target. The target can be, for example, operation of all modules 108 at the same or similar levels with respect to each other, or within predetermined thresholds limits, or conditions. This process is also referred to as balancing or seeking to achieve balance in the operation or operating characteristics of modules 108. The term “balance” as used herein does not require absolute equality between modules 108 or components thereof, but rather is used in a broad sense to convey that operation of system 100 can be used to actively reduce disparities in operation (or operative state) between modules 108 that would otherwise exist.

[0125] MCD 112 can communicate control information to LCD 114 for the purpose of controlling the modules 108 associated with the LCD 114. The control information can be, e.g., a modulation index and a reference signal as described herein, a modulated reference signal, or otherwise. Each LCD 114 can use (e.g., receive and process) the control information to generate switch signals that control operation of one or more components (e.g., a converter) within the associated module(s) 108. In some embodiments, MCD 112 generates the switch signals directly and outputs them to LCD 114, which relays the switch signals to the intended module component.

[0126] All or a portion of control system 102 can be combined with an external control device 104 that controls one or more other aspects of the mobile or stationary application. When integrated into this shared or common control device (or subsystem), control of system 100 can be implemented in any desired fashion, such as one or more software applications executed by processing circuitry of the shared device, with hardware of the shared device, or a combination thereof. Non-exhaustive examples of external control devices 104 include: a vehicular ECU or MCU having control capability for one or more other vehicular functions (e.g., motor control, driver interface control, traction control, etc.); a grid or micro-grid controller having responsibility for one or more other power management functions (e.g., load interfacing, load power requirement forecasting, transmission and switching, interface with charge sources (e.g., diesel, solar, wind), charge source power forecasting, back up source monitoring, asset dispatch, etc.); and a data center control subsystem (e.g., environmental control, network control, backup control, etc.).

[0127] FIGs. ID and IE are block diagrams depicting example embodiments of a shared or common control device 132 (or system) in which control system 102 can be implemented.In FIG. ID, common control device 132 includes MCD 112 and external control device 104. MCD 112 includes an interface 141 for communication with LCDs 114 over path 115, as well as an interface 142 for communication with external control device 104 over internal communication bus 136. External control device 104 includes an interface 143 for communication with MCD 112 over bus 136, and an interface 144 for communication with other entities (e.g., components of the vehicle or grid) of the overall application over communication path 136. In some embodiments, common control device 132 can be integrated as a common housing or package with control devices 112 and 104 implemented as discrete integrated circuit (IC) chips or packages contained therein.

[0128] In FIG. IE, external control device 104 acts as common control device 132, with the main control functionality implemented as a component within device 104. MCD 112 can be or include software or other program instructions stored and / or hardcoded within memory of external control device 104 and executed by processing circuitry thereof. The component can also contain 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 interface (API)) for communication with the operating software of external control device 104. External control device 104 can manage communication with LCDs 114 over interface 141 and other devices over interface 144. In various embodiments, control devices 104 and / or 132 can be integrated as a single IC chip, can be integrated into multiple IC chips in a single package, or integrated as multiple semiconductor packages within a common housing.

[0129] In the embodiments of FIGs. ID and IE, the main control functionality of control system 102 is shared in common control device 132, however, other divisions of shared control are permitted. For example, part of the main control functionality can be distributed between common device 132 and a dedicated MCD 112. In another example, both the main control functionality and at least part of the local control functionality can be implemented in common device 132 (e.g., with the remaining local control functionality implemented in LCDs 114). In some embodiments, all of control system 102 is implemented in a common control device 132 (or system). In some embodiments, local control functionality is implemented within a device shared with another component of each module 108, such as a Battery Management System (BMS).

[0130] In any of these embodiments, all or a portion of control system 102 and external control device 104, as well as various interfaces (e.g., power interfaces 151 and 152 or switchable interface 154) can be integrated into a power and control distribution assembly(PCDA) which acts as a centralized hub for power and control connections for system 100. System 100 can provide power for control system 102 through internal power connections (e.g., buses) of PCDA. Control system 102 and / or external control device 104 can provide control signals and communicate with other components related to power distribution and charging of system 100 that may also be integrated into PCDA, such as routing circuity, switches / relays, sensors, safety disconnects, power buses, power converters, transformers, auxiliary control devices, auxiliary drive units (e.g., for mobile applications), etc. For example, in embodiments with control system 102 configured as a single device (e.g., FIG. 1 A), control system 102 can be a component of PCDA, and external control device 104 may be integrated or external to PCDA. As another example, in embodiments with control system 102 implemented as MCD 112 and one or more LCDs 114 (e.g., FIGs. 1B-1C), MCD 112 can be a component of PCDA and external control device 104 may be integrated or external to PCDA. As yet another example, in embodiments with MCD 112 and external control device 104 implemented as a common control device 132 (e.g., FIGs. 1D-1E), common control device 132 can be a component of PCDA.Section 3: Examples of Modules within Cascaded Energy Systems

[0131] Module 108 includes one or more energy sources 206, a power electronics converter 202 and, if desired, an energy buffer 204. In some embodiments, such as those pertaining to intermittent charging, module 108 can include multiple (e.g., two) power converters. FIGs. 2A-2B are block diagrams depicting additional example 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. The embodiments are described herein with reference to voltage converters, although the embodiments are not limited to such. Converter 202 can be configured to convert a direct current (DC) signal from energy source 206 into an alternating current (AC) signal and output it over power connection 110 (e.g., an inverter). Converter 202 can also receive an AC or DC charge signal over connection 110 and apply it to energy source 206 with either polarity in a continuous or pulsed (e.g., square wave) 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, converter 202 includes only switches and the converter (and the module as a whole) does not include a transformer.

[0132] Alternatively or in addition, converter 202 can be configured to perform AC-to-DC conversion (e.g., a rectifier) such as to charge a DC energy source from an AC source, DC-to-DC conversion, and / or AC to AC conversion (e.g., in combination with an AC -DC converter). In some embodiments, such as to perform 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 conversions with only power switches, power diodes, or other semiconductor devices and without a transformer.

[0133] Energy source 206 is preferably a robust energy storage device capable of outputting direct current and having an energy density suitable for energy storage applications for electrically powered devices. Energy source 206 can be an electrochemical battery, such as a single battery cell or multiple battery cells connected together in a battery module or array, or any combination thereof. FIGs. 4A-4D are schematic diagrams depicting example embodiments of energy source 206 configured as a single battery cell 402 (FIG. 4A), a battery module with a series connection of multiple (e.g., four) cells 402 (FIG. 4B), a battery module with a parallel connection of single cells 402 (FIG. 4C), and a battery module with a parallel connection with legs having two cells 402 each (FIG. 4D). A non-exhaustive list of examples of battery types is set forth elsewhere herein.

[0134] Energy source 206 can also be a high energy density (HED) capacitor, such as an ultracapacitor or supercapacitor. An HED capacitor can be configured as a double-layer capacitor (electrostatic charge storage), pseudocapacitor (electrochemical charge storage), hybrid capacitor (electrostatic and electrochemical), or otherwise, as opposed to a solid dielectric type of a typical electrolytic capacitor. The HED capacitor can have an energy density of 10 to 100 times (or higher) that of an electrolytic capacitor, in addition to a higher capacity. For example, HED capacitors can have a specific energy greater than 1.0 watt hours per kilogram (Wh / kg), and a capacitance greater than 10-100 farads (F). As with the batteries 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., series, parallel, or a combination thereof).

[0135] Energy source 206 can also be a fuel cell. The fuel cell can be a single fuel cell, multiple fuel cells connected in series or parallel, or a fuel cell module. Examples of fuel cell types include proton-exchange membrane fuel cells (PEMFC), phosphoric acid fuel cells (PAFC), solid acid fuel cells, alkaline fuel cells, high-temperature fuel cells, solid oxide fuel cells, molten electrolyte fuel cells, and others. As with the batteries described with respect toFIGs. 4A-4D, energy source 206 can be configured as a single fuel cell or multiple fuel cells connected together in an array (e.g., series, parallel, or a combination thereof). The aforementioned examples of source classes (e.g., batteries, capacitors, and fuel cells) and types (e.g., chemistries and / or structural configurations within each class) are not intended to form an exhaustive list, and those of ordinary skill in the art will recognize other variants that fall within the scope of the present subject matter.

[0136] Energy buffer 204 can dampen or filter fluctuations in current across the DC line or link (e.g., +VDCL and -VDCL as described below), to assist in maintaining stability in the DC link voltage. These fluctuations can be relatively low (e.g., kilohertz) or high (e.g., megahertz) frequency fluctuations or harmonics caused by the switching of converter 202, or other transients. These fluctuations can be absorbed by buffer 204 instead of being passed to source 206 or to ports IO3 and IO4 of converter 202.

[0137] Power connection 110 is a connection for transferring energy or power to, from, and through module 108. Module 108 can output energy from energy source 206 to power connection 110, where it can be transferred to other modules of the system or to a load. Module 108 can also receive energy from other modules 108 or a charging source (DC charger, single-phase charger, multiphase charger) over power connection 110. Signals can also be passed through module 108 bypassing energy source 206. The routing of energy or power into and out of module 108 is performed by converter 202 under the control of LCD 114 (or another entity of control system 102).

[0138] In the embodiment of FIG. 2A, LCD 114 is implemented as a component separate from module 108 (e.g., not within a shared module housing) and is connected to and capable of communication with converter 202 via communication path 116. In the embodiment of FIG. 2B, LCD 114 is included as a component of module 108 and is connected to and capable of communication with converter 202 via internal communication path 118 (e.g., a shared bus or discrete connections). LCD 114 can also be capable of receiving signals from, and transmitting signals to, energy buffer 204, and / or energy source 206 over paths 116 or 118.

[0139] Module 108 can also include monitor circuitry 208 configured to monitor (e.g., collect, sense, measure, and / or determine) one or more aspects of module 108 and / or the components thereof, such as voltage, current, temperature or other operating parameters that constitute status information (or can be used to determine status information by, e.g., LCD 114). A main function of the status information is to describe the state of the one or moreenergy sources 206 of the module 108 to enable determinations as to how much to utilize the energy source in comparison to other sources in system 100, although status information describing the state of other components (e.g., voltage, temperature, and / or presence of a fault in buffer 204, temperature and / or presence of a fault in converter 202, presence of a fault elsewhere in module 108, etc.) can be used in the utilization determination as well. Monitor circuitry 208 can include one or more sensors, shunts, dividers, fault detectors, Coulomb counters, controllers, or other hardware and / or software configured to monitor such aspects. 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, monitor circuitry 208 can be part of or shared with a Battery Management System (BMS) for a battery module 206. Discrete circuitry is not needed to monitor each type of status information, as more than one type of status information can be monitored with a single circuit or device, or otherwise algorithmically determined without the need for additional circuits.

[0140] LCD 114 can receive status information (or raw data) about the components of a module 108 over communication paths 116, 118. LCD 114 can also transmit information to the components of the module 108 over paths 116, 118. Paths 116 and 118 can include diagnostics, 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 converter 202 and / or one or more signals that request the status information from module components. For example, LCD 114 can cause the status information to be transmitted over paths 116, 118 by requesting the status information directly, or by applying a stimulus (e.g., voltage) to cause the status information to be generated, in some cases in combination with switch signals that place converter 202 in a particular state.

[0141] The physical configuration or layout of module 108 can take various forms. In some embodiments, module 108 can include a common housing in 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 in discrete housings that are secured together. FIG. 2C is a block diagram depicting an example embodiment of a module 108 having a first housing 220 that holds an energy source 206 of the module and accompanying electronics (e.g., monitor circuitry 208), a second housing 222 that holds module electronics such as converter 202, energy buffer 204, and their accompanying electronics (e.g., monitor circuitry 208), and athird housing 224 that holds LCD 114 (not shown) for the module 108. In alternative embodiments, the module electronics and LCD 114 can be housed within the same single housing. In still other embodiments, the module electronics, LCD 114, and energy source(s) 206 can be housed within the same single housing for the module 108. Electrical connections between the various module components can proceed through the housings 220, 222, 224 and can be exposed on any of the housing exteriors for connection with other devices such as other modules 108 or MCD 112.

[0142] Modules 108 of system 100 can be physically arranged with respect to each other in various configurations that depend on the needs of the application and the number of loads. For example, in a stationary application where system 100 provides power for a microgrid, modules 108 can be placed in one or more racks or other frameworks. Such configurations may be suitable for larger mobile applications as well, such as maritime vessels.Alternatively, modules 108 can be secured together and located within a common housing, referred to as a pack. A rack or a pack may have its own dedicated cooling system shared across all modules. Pack configurations are useful for smaller mobile applications such as electric cars. System 100 can be implemented with one or more racks (e.g., for parallel supply to a microgrid) or one or more packs (e.g., serving different motors of the vehicle), or a combination thereof. FIG. 2D is a block diagram depicting an example embodiment of system 100 configured as a pack with nine modules 108 electrically and physically coupled together within a common housing 230.

[0143] Examples of these and further configurations are described in Int’l. Appl. No. PCT / US20 / 25366, filed March 27, 2020, and titled Module-Based Energy Systems Capable of Cascaded and Interconnected Configurations, and Methods Related Thereto, which is incorporated by reference herein in its entirety for all purposes.

[0144] FIGs. 3A-3C are block diagrams depicting example embodiments of modules 108 having various electrical configurations. These embodiments are described as having one LCD 114 per module 108, with the LCD 114 housed within the associated module, but can be configured otherwise as described herein. FIG. 3 A depicts a first example configuration of a module 108 A within system 100. Module 108 A includes energy source 206, energy buffer 204, and converter 202A. Each component has power connection ports (e.g., terminals, connectors) into which power can be input and / or from which power can be output, referred to herein as IO ports. Such ports can also be referred to as input ports or output ports depending on the context.

[0145] Energy source 206 can be configured as any of the energy source types described herein (e.g., a battery as described with respect to FIGs. 4A-4D, an HED capacitor, a fuel cell, or otherwise). Ports 101 and 102 of energy source 206 can be connected to ports IO1 and 102, respectively, of energy buffer 204. Energy buffer 204 can be configured to buffer or filter high and low-frequency energy pulsations arriving at buffer 204 through converter 202, which can otherwise degrade the performance of module 108. The topology and components for buffer 204 are selected to accommodate the maximum permissible amplitude of these high-frequency voltage pulsations. Several (non-exhaustive) example embodiments of energy buffer 204 are depicted in the schematic diagrams of FIGs. 5A-5K which include both passive and actively controlled energy buffers.

[0146] FIGs. 5A-5C show example embodiments of passive energy buffers 204. In FIG. 5A, buffer 204 is an electrolytic and / or film capacitor CEB. In FIG. 5B, buffer 204 is a Z- source network 710, formed by two inductors LEBI and LEB2, and two electrolytic and / or film capacitors CEBI and CEB2. In FIG. 5C, buffer 204 is a quasi Z-source network 720, formed by two inductors LEBI and LEB2, two electrolytic and / or film capacitors CEBI and CEB2, and a diode DEB.

[0147] FIGs. 5D-5K show example embodiments of active energy buffers 204 that can be controlled by control system 102 (e.g., LCD 114) over communication path 118-2. In these embodiments, control system 102 can vary filter parameters (e.g., cutoff frequency, frequency roll-off, etc.), eliminate harmonic currents, and / or bypass a passive energy buffer.

[0148] In FIG. 5D, active buffer 204 includes an on / off switch 1108-EB and an electrolytic or film capacitor CEB. On / off switch 1108-EB is a switch having an open state and a closed state, e.g., a single pole single throw (SPST) switch. On / off switch 1108-EB defaults to a closed state such that an anode of the capacitor CEB is connected between ports IO1 and IO3, and a cathode of the capacitor CEB is connected between ports IO2 and IO4. Application of a control signal by control system 102 causes on / off switch 1108-EB to open which disconnects the anode of the capacitor CEB. FIG. 5E is another example embodiment of an active energy buffer 204 configured similarly to that of FIG. 5D but with a solid-state relay (SSR) circuit 1221-EB in place of on / off switch 1108-EB. The conducting state of SSR circuit 1221-EB is controllable by a control port 1206-EB which allows control system 102 to connect and disconnect the anode of capacitor CEB. Example embodiments of SSR circuits 1221 are shown in FIGs. 12C-12E and described in more detail in Section 8.

[0149] In FIG. 5F, active buffer 204 includes an on / off switch 1108-EB and two electrolytic and / or film capacitors CEBI and CEB2 connected in parallel. Here, the anode of first capacitor CEBI is selectively connectable via switch 1108-EB, while the second capacitor CEB2 is continuously connected. Since the capacitance of parallel capacitors is additive, control system 102 can connect or disconnect the anode of first capacitor CEBI to increase or decrease the effective capacitance of active buffer 204. Active buffer 204 of FIG. 5G is configured similarly to that of FIG. 5F but with an SSR circuit 1221-EB in place of on / off switch 1108-EB and therefore operates in an analogous manner. In some embodiments, active buffers 204 of FIGs. 5F-5G can include an additional switch (e.g., an on / off switch 1108 or an SSR circuit 1221) to allow selective connection of the anode of second capacitor CEB2, providing increased variation of the effective capacitance. Along similar lines, an active buffer 204 can include more than two capacitors connected in parallel, along with one or more controllable switches to selectively connect one or more of the capacitors.

[0150] FIG. 5H shows another example embodiment of an active energy buffer 204 that includes two switch units 210-EB1 and 210-EB2 that can be controlled by control system 102 for bypassing a passive energy buffer circuit 204A, e.g., a Z-source network 710 or 720. Switch units 210-EB can alternate between two conducting configurations to allow selective connection of passive buffer 204 A. A first configuration of switch units 210-EB provides a conducting pathway between ports 2 and 3 and open circuits port 1, such that the circuit seen between ports IO 1-IO4 of active buffer 204 is equivalent to that of passive buffer 204A. A second configuration of switch units 210-EB provides a conducting pathway between ports 1 and 3 and opens circuits port 2, which effectively bypasses passive buffer 204A. Active energy buffer 204 in FIG. 51 is configured similarly to the embodiment of FIG. 5H but includes a second passive energy buffer 204B, e.g., an electrolytic (or film) capacitor, or a Z- source network 710 or 720. In this embodiment, control system 102 can selectively connect the first passive buffer 204A to add or subtract its filtering effects with second passive buffer 204B, similar to active buffers 204 in FIGs. 5F and 5G.

[0151] FIGs. 5L-5N show example embodiments of switch units 210 that can be implemented in the active energy buffers 204 of FIGs. 5H and 51. In FIG. 5L, switch unit 210 is a two-conductive position (TCP) switch 1108 (e.g., a single pole double throw (SPDT) switch) that allows selective connection of port 1 or port 2 to port 3. Control system 102 can alternate between the two conducting configurations of switch unit 210 via a control signal to TCP switch 1108. In FIG. 5M, switch unit 210 includes two on / off switches 1108-1 and1108-2. Here, when one of the on / off switches 1108-1 or 1108-2 is in an open state, and the other is in a closed state, either port 1 or port 2 is connected to port 3. Control system 102 can then alternate between the two conducting configurations of switch unit 210 by applying a control signal to both on / off switches 1108-1 and 1108-2. In FIG. 5N, switch unit 210 includes two SSR circuits 1221-1 and 1221-2 in place of on / off switches 1108-1 and 1108-2, respectively, and therefore operates in an analogous manner to that of FIG. 5M.

[0152] The embodiments of active energy buffers 204 in FIGs. 5D-5I are particularly suited for situations involving pulse charging of modules 108. For example, when a module 108 receives a DC or AC charge signal over connection 110, a converter 202 of the module 108 can convert the charge signal into a pulsed (e.g., square) wave and apply it to an energy source 206 of the module 108. A high capacitance capacitor (e.g., an electrolytic or film capacitor) would generally damp the high-frequency components of the pulsed wave, e.g., causing smoothing or rounding, which reduces the effectiveness of pulsed charging. For active buffers 204 in FIGs. 5D-5E, control system 102 can simultaneously disconnect the anode of capacitor CEB, allowing the converter 202 to apply the pulsed wave to the energy source 206 without damping. Similarly, for active buffers 204 in FIGs. 5F-5G, control system 102 can simultaneously disconnect the anode of first capacitor CEBI to reduce the effective capacitance, allowing the converter 202 to apply the pulsed wave to the energy source 206 with reduced (or negligible) damping. Control system 102 can achieve a similar effect using active buffers 204 in FIGs. 5H-5I, by bypassing passive energy buffer 204A to eliminate (or reduce) its filtering effects on pulsed waves output by converter 202.

[0153] FIGs. 5J-5K show additional example embodiments of actively controlled energy buffers 204. In FIG. 5J, active buffer 204 is a half-bridge active filter formed by two switches SEBI and SEB2, two electrolytic and / or film capacitors CEBI and CEB2, and an inductor LEB. FIG. 5J shows another example embodiment of a half-bridge active filter configured similarly to that of FIG. 51 but with the capacitors CEBI and CEB2 and inductor LEB replaced with two passive energy buffer circuits 204A and 204B, e.g., Z-source networks 710 and / or 720.

[0154] 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 202 A configured as a DC- AC converter that can receive a DC voltage at ports IO1 and IO2 and switch to generate pulses at ports IO3 and IO4. Converter 202 A can include multiple switches, and here converter 202A includes four switches S3, S4, S5, and S6arranged in a full-bridge configuration. Control system 102 or LCD 114 can independently control each switch via control input lines 118-3 to each gate.

[0155] The switches can be any suitable switch type, such as power semiconductors like the metal-oxide-semiconductor field-effect transistors (MOSFETs) shown here, insulated gate bipolar transistors (IGBTs), or gallium nitride (GaN) transistors. Semiconductor switches can operate at relatively high switching frequencies, thereby permitting converter 202 to be operated in pulse-width modulated (PWM) mode if desired, and to respond to control commands within a relatively short interval of time. This can provide a high tolerance of output voltage regulation and fast dynamic behavior in transient modes.

[0156] In this embodiment, a DC line voltage VDCL can be applied to converter 202 between ports IO1 and IO2. By connecting VDCL to ports IO3 and IO4 by different combinations of switches S3, S4, S5, and S6, converter 202 can generate three different voltage outputs at ports IO3 and 104: +VDCL, 0, and -VDCL. A switch signal provided to each switch controls whether the switch is on (closed) or off (open). To obtain +VDCL, switches S3 and S6 are turned on while S4 and S5 are turned off, whereas -VDCL can be obtained by turning on switches S4 and S5 and turning off S3 and S6. The output voltage can be set to zero (including near zero) or a reference voltage by turning on S3 and S5 with S4 and S6 off, or by turning on S4 and S6 with S3 and S5 off. These voltages can be output from module 108 over power connection 110. Ports IO3 and 104 of converter 202 can be connected to (or form) module IO ports 1 and 2 of power connection 110, to generate the output voltage for use with output voltages from other modules 108.

[0157] The 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 graph of voltage versus time depicting an example of an output voltage waveform 802 of converter 202. For ease of description, the embodiments herein will be described in the context of a PWM control technique, although the embodiments are not limited to such. Other classes of techniques can be used. One alternative class is based on hysteresis, examples of which are described in IntT Publ. Nos. WO 2018 / 231810A1, WO 2018 / 232403A1, and WO 2019 / 183553A1, which are incorporated by reference herein for all purposes.

[0158] Each module 108 can be configured with multiple energy sources 206 (e.g., two, three, four, or more). Each energy source 206 of module 108 can be controllable (switchable) to supply power to connection 110 (or receive power from a charge source) independent of the other sources 206 of the module. For example, all sources 206 can output power to connection 110 (or be charged) at the same time, or only one (or a subset) of sources 206 can supply power (or be charged) at any one time. In some embodiments, the sources 206 of the module can exchange energy between them, 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., battery, HED capacitor, fuel cell). Each of the sources 206 can be the same class (e.g., each can be a battery, each can be an HED capacitor, or each can be a fuel cell), or a different class (e.g., a first source can be a battery and a second source can be an HED capacitor or fuel cell, or a first source can be an HED capacitor and a second source can be a fuel cell).

[0159] FIG. 3B is a block diagram depicting an example embodiment of a module 108B in a dual energy source configuration with a primary energy source 206A and secondary energy source 206B. Ports IO1 and IO2 of primary source 206 A can be connected to ports IO1 and IO2 of energy buffer 204. Module 108B includes a converter 202B having 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 (also connected to port 104 of buffer 204).

[0160] In this example embodiment of module 108B, primary energy source 206A, along with the other modules 108 of system 100, supplies the average power needed by the load. Secondary source 206B can serve the function of assisting energy source 206 by providing additional power at load power peaks, absorbing excess power, or otherwise.

[0161] As mentioned above, both primary source 206A and secondary source 206B can be utilized simultaneously or at separate times depending on the switch state of converter 202B. At the same time, an electrolytic and / or a film capacitor (CES) can be placed in parallel with source 206B as depicted in FIG. 4E to act as an energy buffer for the source 206B, or energy source 206B can be configured to utilize an HED capacitor in parallel with another energy source (e.g., a battery or fuel cell) as depicted in FIG. 4F.

[0162] FIGs. 6B and 6C are schematic views depicting example embodiments of converters 202B and 202C, respectively. Converter 202B includes switch circuitry portions 601 and 602 A. Portion 601 includes switches S3 through S6 configured as a full-bridge in asimilar manner to converter 202A, and is configured to selectively couple 101 and 102 to either of 103 or 104, thereby changing the output voltages of module 108B. Portion 602 A includes switches SI and S2 configured as a half-bridge and coupled between ports 101 and 102. A coupling inductor Lc is connected between port 105 and a nodel present between switches SI and S2 such that switch portion 602A is a bidirectional converter that can regulate (boost or buck) voltage (or inversely current). Switch portion 602A can generate two different voltages at nodel, which are +VDCL2 and 0, referenced to port 102, which can be at virtual zero potential. The current drawn from or input to energy source 206B can be controlled by regulating the voltage on coupling inductor Lc, using, for example, a pulsewidth modulation technique or a hysteresis control method for commutating switches SI and S2. Other techniques can also be used.

[0163] Converter 202C differs from converter 202B in that switch portion 602B includes switches SI and S2 configured as a half-bridge and coupled between ports 105 and 102. A coupling inductor Lc is connected between port 101 and a nodel present between switches SI and S2 such that switch portion 602B is configured to regulate voltage. In general, for converter 202B in FIG. 6B, the voltage between ports 105 and 102 is always lower than the voltage between ports 101 and 102. For converter 202C in FIG 6C, the voltage between ports 105 and 102 is always higher than the voltage between ports 101 and 102.

[0164] Control system 102 or LCD 114 can independently control each switch of converters 202B and 202C via control input lines 118-3 connected to respective gate terminals of the switches. In these embodiments and that of FIG. 6A, LCD 114 (not MCD 112) generates the switching signals for the converter switches. Alternatively, MCD 112 can generate the switching signals, which can be communicated directly to the switches, or relayed by LCD 114. In some embodiments, driver circuitry for generating the switching signals can be present in or associated with MCD 112 and / or LCD 114.

[0165] A zero voltage configuration for converter 202 (turning on S3 and S5 with S4 and S6 off, or turning on S4 and S6 with S3 and S5 off) can also be referred to as a bypass state for a given module 108. This bypass state can be entered if a fault is detected in the given module 108, or if a system fault is detected warranting shut-off of more than one (or all modules) in an array or system 100. A fault in the module 108 can be detected by LCD 114 and the control switching signals for converter 202 can be set to engage the bypass state without intervention by MCD 112. Alternatively, fault information for a given module 108 can be communicated by LCD 114 to MCD 112, and MCD 112 can then decide whether toengage the bypass state, and if so, can communicate instructions to engage the bypass state to the LCD 114 associated with the module 108 having the fault, at which point LCD 114 can output switching signals to cause engagement of the bypass state.

[0166] In embodiments where a module 108 includes three or more 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 leading to an additional switch circuitry portion 602A or 602B, depending on the needs of the particular source. For example, a dual source converter 202 can include both switch portions 602 A and 602B.

[0167] Modules 108 with multiple energy sources 206 are capable of performing additional functions such as energy sharing between sources 206, energy capture from within the application (e.g., regenerative braking), charging of the primary source 206 A by the secondary source 206B even while the overall system 100 is in a state of discharge, and active filtering of the module output. The active filtering function can also be performed by modules having a typical electrolytic capacitor instead of a secondary energy source.Examples of these functions are described in more detail in IntT. Appl. No. PCT / US20 / 25366, filed March 27, 2020, and titled Module-Based Energy Systems Capable of Cascaded and Interconnected Configurations, and Methods Related Thereto, and IntT. Publ. No. WO 2019 / 183553, filed March 22, 2019, and titled Systems and Methods for Power Management and Control, both of which are incorporated by reference herein in their entireties for all purposes.

[0168] Each module 108 can be configured to supply power to one or more auxiliary loads with its one or more energy sources 206. Auxiliary loads are loads that require lower voltages than the primary load 101. Examples of auxiliary loads can include, for example, an on-board electrical network of an EV, or an HVAC system of the EV. The primary load 101 of system 100 can include, for example, one or more phases of an electric vehicle motor or an electrical grid.

[0169] FIG. 3C is a block diagram depicting an example embodiment of a module 108C configured to supply power to a first auxiliary load 301 and a second auxiliary load 302, where module 108C includes an energy source 206, an energy buffer 204, and a converter 202B coupled together in a manner similar to that of FIG. 3B. First auxiliary load 301 requires a voltage equivalent to that supplied from 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 auxiliaryload 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 105 and 102, respectively, of converter 202B. Converter 202B can include switch portion 602 having coupling inductor Lc coupled to port IO5 (FIG. 6B). Energy supplied by source 206 can be supplied to second auxiliary load 302 through switch portion 602 of converter 202B. In this embodiment, it is assumed that load 302 has an input capacitor (a capacitor can be added to module 108C if not), so switches SI and S2 can be commutated to regulate the voltage on and current through coupling inductor Lc and thus produce a stable constant voltage for load 302. This regulation can step down the voltage of source 206 to the lower magnitude voltage required by load 302.

[0170] Module 108C can thus be configured to supply one or more first auxiliary loads in the manner described with respect to load 301, with the one or more first loads coupled to IO ports 3 and 4. Module 108C can also be configured to supply one or more second auxiliary loads in the manner described with respect to load 302. If multiple second auxiliary loads 302 are present, then for each additional load 302, module 108C can be scaled with additional dedicated module output ports (like 5 and 6), an additional dedicated switch portion 602, and an additional converter IO port coupled to the additional portion 602.

[0171] Energy source 206 can thus supply power for any number of auxiliary loads (e.g., 301 and 302), as well as the corresponding portion of system output power needed by primary load 101. Power flow from source 206 to the various loads can be adjusted as desired.

[0172] Module 108 can be configured as needed with two or more energy sources 206 (FIG. 3B) and to supply first and / or second auxiliary loads (FIG. 3C) through the addition of a 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. Module 108 can also be configured as an interconnection module to exchange energy (e.g., for balancing) between two or more arrays, two or more packs, or two or more systems 100 as described further herein. This interconnection functionality can likewise be combined with multiple source and / or multiple auxiliary load supply capabilities.

[0173] Control system 102 can perform various functions with respect to the components of modules 108 A, 108B, and 108C. These functions can include management of the utilization (amount of use) of each energy source 206, protection of energy buffer 204 from over-current, over-voltage, and high-temperature conditions, and control and protection of converter 202.

[0174] For example, to manage (e.g., adjust by increasing, decreasing, or maintaining) 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 of, preferably all, voltages of each elementary component independent of the other components (e.g., each individual battery cell, HED capacitor, and / or fuel cell) of the source 206, or the voltages of groups of elementary components as a whole (e.g., voltage of the battery array, HED capacitor array, and / or fuel cell array). Similarly, the monitored temperatures and currents can be at least one of, preferably all, temperatures and currents of each elementary component independent of the other components of the source 206, or the temperatures and currents of groups of elementary components as a whole, or any combination thereof. The monitored signals can be status information, with which LCD 114 can perform one or more of the following: calculation or determination of a real capacity, actual State of Charge (SOC), and / or State of Health (SOH) of the elementary components or groups of elementary components; set or output a warning or alarm indication based on monitored and / or calculated status information; and / or transmission of the status information to MCD 112. LCD 114 can receive control information (e.g., a modulation index, synchronization signal) from MCD 112 and use this control information to generate switch signals for converter 202 that manage the utilization of the source 206.

[0175] To protect energy buffer 204, LCD 114 can receive one or more monitored voltages, temperatures, and currents from energy buffer 204 (or monitor circuitry). The monitored voltages can be at least one of, preferably all, voltages of each elementary component of buffer 204 (e.g., of CEB, CEBI, CEB2, LEBI, LEB2, DEB) independent of the other components, or the voltages of groups of elementary components or 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 of, preferably all, temperatures and currents of each elementary component of buffer 204 independent of the other components, or the temperatures and currents of groups of elementary components or buffer 204 as a whole, or any combination thereof. The monitored signals can be status information, with which LCD 114 can perform one or more of the following: set or output a warning or alarm indication; communicate the status information to MCD 112; or control converter 202 to adjust (increase or decrease) the utilization of source 206 and module 108 as a whole for buffer protection.

[0176] To control and protect converter 202, LCD 114 can receive the control information from MCD 112 (e.g., a modulated reference signal, or a reference signal and a modulation index), which can be used with a PWM technique in LCD 114 to generate the control signals for each switch (e.g., SI through S6). LCD 114 can receive a current feedback signal from a current sensor of converter 202, which can be used for overcurrent protection together with one or more fault status signals from driver circuits (not shown) of the converter switches, which can carry information about fault statuses (e.g., short circuit or open circuit failure modes) of all switches of converter 202. Based on this data, LCD 114 can decide on which combination of switching signals to be applied to manage utilization of module 108, and potentially bypass or disconnect converter 202 (and the entire module 108) from system 100.

[0177] If controlling a module 108C that supplies a second auxiliary load 302, LCD 114 can receive one or more monitored voltages (e.g., the voltage between IO ports 5 and 6) and one or more monitored currents (e.g., the current in coupling inductor Lc, which is a current of load 302) in module 108C. Based on these signals, LCD 114 can adjust the switching cycles (e.g., by adjustment of modulation index or reference waveform) of SI and S2 to control (and stabilize) the voltage for load 302.Section 4: Examples of Cascaded Energy System Topologies

[0178] Two or more modules 108 can be coupled together in a cascaded array that outputs a voltage signal formed by a superposition of the discrete voltages generated by each module 108 within the array. FIG. 7A is a block diagram depicting an example embodiment of a topology for system 100 where N modules 108-1, 108-2, . . . 108-N are coupled together in series to form a serial array 700. In this and all embodiments described herein, N can be any integer greater than one. Array 700 includes a first system IO port SIO1 and a second system IO port SIO2 across which is generated an array output voltage. Array 700 can be used as a DC or single-phase AC energy source for DC or AC single-phase loads, which can be connected to SIO1 and SIO2 of array 700. FIG. 8 A is a plot of voltage versus time depicting an example output signal produced by a single module 108 having a 48 volt energy source. FIG. 8B is a plot of voltage versus time depicting an example single-phase AC output signal generated by array 700 having six 48V modules 108 coupled in series.

[0179] System 100 can be arranged in a broad variety of different topologies to meet varying needs of the applications. System 100 can provide multiphase power (e.g., two-phase, three-phase, four-phase, five-phase, six-phase, etc.) to a load by use of multiple arrays 700, where each array can generate an AC output signal having a different phase angle.

[0180] 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, formed by a series connection of N modules 108. The two arrays 700-PA and 700-PB can each generate a single-phase AC signal, where the two AC signals have 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 in turn can serve as a first output of each array that can provide two-phase power to a load (not shown). Alternatively, ports SIO1 and SIO2 can be connected to provide single-phase power from two parallel arrays. IO port 2 of module 108-N of each array 700- PA and 700- PB can serve as a second output for each array 700- PA and 700- PB on the opposite end of the array from system IO ports SIO1 and SIO2, and can be coupled together at a common node and optionally used for an additional system IO port SIO3 if desired, which can serve as a neutral. This common node can be referred to as a rail, and IO port 2 of modules 108-N of each array 700 can be referred to as being on the rail side of the arrays.

[0181] FIG. 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, formed by a series connection of N modules 108. The three arrays 700-PA, 700-PB, and 700-PC can each generate a single-phase AC signal, where the three AC signals have 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 in turn can provide three-phase power to a load (not shown). IO port 2 of module 108-N of each array 700-PA, 700-PB, and 700-PC can be coupled together at a common node and optionally used for an additional system IO port SIO4 if desired, which can serve as a neutral.

[0182] The concepts described with respect to the two-phase and three-phase embodiments of FIGs. 7B and 7C can be extended to systems 100 generating still more phases of power. For example, a non-exhaustive list of additional examples includes: system 100 having four arrays 700, each of which is configured to generate a single-phase AC signal having a different phase angle (e.g., 90 degrees apart): system 100 having five arrays 700, each of which is configured to generate a single-phase AC signal having a different phase angle (e.g.,72 degrees apart); and system 100 having six arrays 700, each array configured to generate a single-phase AC signal having a different phase angle (e.g., 60 degrees apart).

[0183] System 100 can be configured such that arrays 700 are interconnected at electrical nodes between modules 108 within each array. FIG. 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 greater, coupled with a second series connection of N modules 108, where N is two or greater. The delta configuration is formed by the interconnections between 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 with IO port 2 of module 108-M and IO port 1 of module 108-(M+l) of array 700-PA, IO port 2 of module 108-(M+N) of array 700-PB is coupled with IO port 2 of module 108-M and IO port 1 of module 108-(M+l) of array 700-PC, and IO port 2 of module 108-(M+N) of array 700-PA is coupled with IO port 2 of module 108-M and IO port 1 of module 108-(M+l) of array 700-PB.

[0184] 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 except with different cross-connections. In this embodiment, IO port 2 of module 108-M of array 700-PC is coupled with IO port 1 of module 108-1 of array 700-PA, IO port 2 of module 108-M of array 700-PB is coupled with 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 with IO port 1 of module 108-1 of array 700-PB. The arrangements of FIGs. 7D and 7E can be implemented with as little as two modules in each array 700. Combined delta and series configurations enable an effective exchange of energy between all modules 108 of the system (interphase balancing) and phases of a power grid or load, and also allows reducing the total number of modules 108 in an array 700 to obtain the desired output voltages.

[0185] In the embodiments described herein, although it is advantageous for the number of modules 108 to be the same in each array 700 within system 100, such is not required and different arrays 700 can have differing numbers of modules 108. Further, each array 700 can have modules 108 that are all of the same configuration (e.g., all modules are 108 A, all modules are 108B, all modules are 108C, or others) or different configurations (e.g., one or more modules are 108 A, one or more are 108B, and one or more are 108C, or otherwise). As such, the scope of topologies of system 100 covered herein is broad.Section 5: Control Methodology Examples

[0186] As mentioned, control of system 100 can be performed according to various methodologies, such as hysteresis or PWM. Several examples of PWM include space vector modulation and sine pulse width modulation, where the switching signals for converter 202 are generated with a phase-shifted carrier technique that continuously rotates utilization of each module 108 to equally distribute power among them.

[0187] FIGs. 8C-8F are plots depicting an example embodiment of a phase-shifted PWM control methodology that can generate a multilevel output PWM waveform using incrementally shifted two-level waveforms. An X-level PWM waveform can be created by the summation of (X-l) / 2 two-level PWM waveforms. These two-level waveforms can be generated by comparing a reference waveform Vref to carriers incrementally shifted by 360° / (X-l). The carriers are triangular, but the embodiments are not limited to such. A nine- level example is shown in FIG. 8C (using four modules 108). The carriers are incrementally shifted by 3607(9-1) = 45° and compared to Vref. The resulting two-level PWM waveforms are shown in FIG. 8E. These two-level waveforms may be used as the switching signals for semiconductor switches (e.g., SI through S6) of converters 202. As an example with reference 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 and the 180° signal for S6 of the first module 108-1, the 45° signal is for S3 and the 225° signal for S6 of the second module 108-2, the 90 signal is for S3 and the 270 signal is for S6 of the third module 108-3, and the 135 signal is for S3 and the 315 signal is for S6 of the fourth module 108-4. The signal for S3 is complementary to S4 and the signal for S5 is complementary to S6 with sufficient dead-time to avoid shoot-through of each half-bridge. FIG. 8F depicts an example single-phase AC waveform produced by superposition (summation) of output voltages from the four modules 108.

[0188] An alternative is to utilize both a positive and a negative reference signal with the first (N-l) / 2 carriers. A nine-level example is shown in FIG. 8D. In this example, the 0° to 135° switching signals (FIG. 8E) are generated by comparing +Vref to the 0° to 135° carriers of FIG. 8D and the 180° to 315° switching signals are generated by comparing -Vref to the 0° to 135° carriers of FIG. 8D. However, the logic of the comparison in the latter case is reversed. Other techniques such as a state machine decoder may also be used to generate gate signals for the switches of converter 202.

[0189] In multiphase system embodiments, the same carriers 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 carriers of the second phase are shifted by 120 degrees as compared to the carriers of the first phase, and the carriers of the third phase are shifted by 240 degrees as compared to the carriers of the first phase. If a different reference voltage is available for each phase, then the phase information can be carried in the reference voltage and the same carriers can be used for each phase. In many cases, the carrier frequencies will be fixed, but in some example embodiments, the carrier frequencies can be adjusted, which can help to reduce losses in EV motors under high current conditions.

[0190] The appropriate switching signals can be provided to each module by control system 102. For example, MCD 112 can provide Vref and the appropriate carrier signals to each LCD 114 depending upon the module or modules 108 that LCD 114 controls, and the LCD 114 can then generate the switching signals. Or all LCDs 114 in an array can be provided with all carrier signals and the LCD can select the appropriate carrier signals.

[0191] The relative utilization of each module 108 can be adjusted based on status information to perform balancing or of one or more parameters as described herein. Balancing of parameters can involve adjusting utilization to minimize parameter divergence over time as compared to a system where individual module utilization adjustment is not performed. The utilization can be the relative amount of time a module 108 is discharging when system 100 is in a discharge state, or the relative amount of time a module 108 is charging when system 100 is in a charge state.

[0192] As described herein, modules 108 can be balanced with respect to other modules in an array 700, which can be referred to as intra-array or intraphase balancing, and different arrays 700 can be balanced with respect to each other, which can be referred to as inter-array or interphase balancing. Arrays 700 of different subsystems can also be balanced with respect to each other. Control system 102 can simultaneously perform any combination of intraphase balancing, interphase balancing, utilization of multiple energy sources within a module, active filtering, and auxiliary load supply.

[0193] FIG. 9A is a block diagram depicting an example embodiment of an array controller 900 of control system 102 for a single-phase AC or DC array. Array controller 900 can include a peak detector 902, a divider 904, and an intraphase (or intra-array) balancecontroller 906. Array controller 900 can receive a reference voltage waveform (Vr) and status information about each of the N modules 108 in the array (e.g., state of charge (SOCi), temperature (Ti), capacity (Qi), and voltage (Vi)) as inputs, and generate a normalized reference voltage waveform (Vm) and modulation indexes (Mi) as outputs. Peak detector 902 detects the peak (Vpk) of Vr, which can be specific to the phase that controller 900 is operating with and / or balancing. Divider 904 generates Vm by dividing Vr by its detected Vpk. Intraphase balance controller 906 uses Vpk along with the status information (e.g., SOCi, Ti, Qi, Vi, etc.) to generate modulation indexes Mi for each module 108 within the array 700 being controlled.

[0194] The modulation indexes and Vrn can be used to generate the switching signals for each converter 202. The modulation index can be a number between zero and one (inclusive of zero and one). For a particular module 108, the 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 technique described with respect to FIGs. 8C-8F, or according to 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 being controlled to maintain normal or full operation may receive an Mi of one, while a module 108 being controlled to less than normal or full operation may receive an Mi less than one, and a module 108 controlled to cease power output may receive an Mi of zero. This operation can be performed in various ways by control system 102, such as by MCD 112 outputting Vrn and Mi to the appropriate LCDs 114 for modulation and switch signal generation, by MCD 112 performing modulation and outputting the modulated Vrnm to the appropriate LCDs 114 for switch signal generation, or by MCD 112 performing modulation and switch signal generation and outputting the switch signals to the LCDs or the converters 202 of each module 108 directly. Vrn can be sent continually with Mi sent at regular intervals, such as once for every period of the Vm, or once per minute, etc.

[0195] Controller 906 can generate an Mi for each module 108 using any type or combination of types of status information (e.g., SOC, temperature (T), Q, SOH, voltage, current) described herein. For example, when using SOC and T, a module 108 can have a relatively high Mi if SOC is relatively high and temperature is relatively low as compared to other modules 108 in array 700. If either SOC is relatively low or T is relatively high, then that module 108 can have a relatively low Mi, resulting in less utilization than other modules108 in array 700. Controller 906 can determine Mi such that the sum of module voltages does not exceed Vpk. For example, Vpk can be the sum of the products of the voltage of each module’s source 206 and Mi for that module (e.g., Vpk = M1V1+M2V2+M3V3 . . . +MNVN, etc). A different combination of modulation indexes, and thus respective voltage contributions by the modules, may be used but the total generated voltage should remain the same.

[0196] Array controller 900 can control operation, to the extent it does not prevent achieving the power output requirements of the system at any one time (e.g., such as during maximum acceleration of an EV), such that SOC of the energy source(s) in each module 108 remains balanced or converges to a balanced condition if they are unbalanced, and / or such that temperature of the energy source(s) or other component (e.g., energy buffer) in each module remains balanced or converges to a balanced condition if they are unbalanced. Power flow in and out of the modules can be regulated such that a capacity difference between sources does not cause an SOC deviation. Balancing of SOC and temperature can indirectly cause some balancing of SOH. Voltage and current can be directly balanced if desired, but in many embodiments, the main goal of the system is to balance SOC and temperature, and balancing of SOC can lead to a balance of voltage and current in a highly symmetric system where modules are of similar capacity and impedance.

[0197] Since balancing all parameters may not be possible at the same time (e.g., balancing of one parameter may further unbalance another parameter), a combination of balancing any two or more parameters (SOC, T, Q, SOH, V, I) may be applied with priority given to either one depending on the requirements of the application. Priority in balancing can be given to SOC over other parameters (T, Q, SOH, V, I), with exceptions made if one of the other parameters (T, Q, SOH, V, I) reaches a severe unbalanced condition outside a threshold.

[0198] Balancing between arrays 700 of different phases (or arrays of the same phase, e.g., if parallel arrays are used) can be performed concurrently with intraphase balancing. FIG. 9B depicts an example embodiment of an Q-phase (or Q-array) controller 950 configured for operation in an Q-phase system 100, having at least Q arrays 700, where Q is any integer greater than one. Controller 950 can include one interphase (or inter-array) controller 910 and Q intraphase balance controllers 906-PA . . . 906-PQ for phases PA through PQ, as well as peak detector 902 and divider 904 (FIG. 9A) for generating normalized references VrnPA through VrnPQ from each phase-specific reference VrPAthrough VrPQ. Intraphase controllers 906 can generate Mi for each module 108 of each array 700 as described with respect to FIG. 9A. Interphase balance controller 910 is configured or programmed to balance aspects of modules 108 across the entire multi-dimensional system, for example, between arrays of different phases. This may be achieved by injecting common mode to the phases (e.g., neutral point shifting) or through the use of interconnection modules (described herein), or through both. Common mode injection involves introducing a phase and amplitude shift to the reference signals VrPA through VrPQ to generate normalized waveforms VrnPA through VmPQ to compensate for unbalance in one or more arrays, and is described further in IntT. Appl. No. PCT / US20 / 25366 incorporated herein.

[0199] Controllers 900 and 950 (as well as 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, distributed partially or fully among LCDs 114, or may be implemented as discrete controllers independent of MCD 112 and LCDs 114.Section 6: Interconnection (IC) Module Examples

[0200] Modules 108 can be connected between the modules of different arrays 700 for the purposes of exchanging energy between the arrays 700, acting as a source for an auxiliary load, or both. Such modules are referred to herein as interconnection (IC) modules 108IC. IC module 108IC can be implemented in any of the already described module configurations (108A, 108B, 108C) and others to be described herein. IC modules 108IC can include any number of one or more energy sources, an optional energy buffer, switch circuitry for supplying energy to one or more arrays and / or for supplying power to one or more auxiliary loads, control circuitry (e.g., a local control device), and monitor circuitry for collecting status information about the IC module itself or its various loads (e.g., SOC of an energy source, temperature of an energy source or energy buffer, capacity of an energy source, SOH of an energy source, voltage and / or current measurements pertaining to the IC module, voltage and / or current measurements pertaining to the auxiliary load(s), etc.).

[0201] FIG. 10A is a block diagram depicting an example embodiment of a system 100 capable of producing Q-phase power with Q arrays 700-PA through 700-PQ, where Q can be any integer greater than one. In this and other embodiments, IC module 108IC can be located on the rail side of arrays 700 such that the arrays 700 to which module 108IC are connected (arrays 700-PA through 700-PQ in this embodiment) are electrically connected betweenmodule 108IC and outputs (e.g., SIO1 through SIOQ) to the load. Here, module 108IC has Q IO ports for connection to IO port 2 of each module 108-N of arrays 700-PA through 700- PQ. In the configuration depicted here, module 108IC can perform interphase balancing by selectively connecting the one or more energy sources of module 108IC to one or more of the arrays 700-PA through 700-PQ (or to no output, or equally to all outputs, if interphase balancing is not required). System 100 can be controlled by control system 102 (not shown, see FIG. 1 A).

[0202] FIG. 10B is a schematic diagram depicting an example embodiment of module 108IC. In this embodiment, module 108IC includes an energy source 206 connected with energy buffer 204 that in turn is connected with switch circuitry 603. Switch circuitry 603 can include switch circuitry portions 604-PA through 604-PQ for independently connecting energy source 206 to each of arrays 700-PA through 700-PQ, respectively. Various switch configurations can be used for each portion 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 lines 118-3 from LCD 114. This configuration is similar to module 108A described with respect to FIG. 3 A. As described with respect to converter 202, switch circuitry 603 can be configured in any arrangement and with any switch types (e.g., MOSFET, IGBT, Silicon, GaN, etc.) suitable for the requirements of the application.

[0203] Switch circuitry portions 604 are coupled between positive and negative terminals of energy source 206 and have an output that is connected to an IO port of module 108IC. Switch portions 604-PA through 604-PQ can be controlled by control system 102 to selectively couple voltage +Vic or -Vic to the respective module IO ports 1 through Q. Control system 102 can control switch circuitry 603 according to any desired control technique, including the PWM and hysteresis techniques mentioned herein. Here, control system 102 is implemented as LCD 114 and MCD 112 (not shown). LCD 114 can receive monitoring data or status information from monitor circuitry of module 108IC. This monitoring data and / or other status information derived from this monitoring data can be output to MCD 112 for use in system control as described herein. LCD 114 can also receive timing information (not shown) for purposes of synchronization of modules 108 of the system 100 and one or more carrier signals (not shown), such as the sawtooth signals used in PWM (FIGs. 8C-8D).

[0204] For interphase balancing, proportionally more energy from source 206 can be supplied to any one or more of arrays 700-PA through 700-PQ that is relatively low oncharge as compared to other arrays 700. Supply of this supplemental energy to a particular array 700 allows the energy output of those cascaded modules 108-1 through 108-N in that array 700 to be reduced relative to the unsupplied phase array(s).

[0205] For instance, in some example embodiments applying PWM, LCD 114 can be configured to receive the normalized voltage reference signal (Vm) (from MCD 112) for each of the one or more arrays 700 that module 108IC is coupled to, e.g., VrnPA through VmPQ. LCD 114 can also receive modulation indexes MiPA through MiPQ for the switch units 604-PA through 604-PQ for each array 700, respectively, from MCD 112. LCD 114 can modulate (e.g., multiply) each respective Vm with the modulation index for the switch section coupled directly to that array (e.g., VmA multiplied by MiA) and then utilize a carrier signal to generate the control signal(s) for each switch portion 604. In other embodiments, MCD 112 can perform the modulation and output modulated voltage reference waveforms for each switch portion 604 directly to LCD 114 of module 108IC. In still other embodiments, all processing and modulation can occur by a single control entity that can output the control signals directly to each switch portion 604.

[0206] This switching can be modulated such that power from energy source 206 is supplied to the array(s) 700 at appropriate intervals and durations. Such methodology can be implemented in various ways.

[0207] Based on the collected status information for system 100, such as the present capacity (Q) and SOC of each energy source in each array, MCD 112 can determine an aggregate charge for each array 700 (e.g., aggregate charge for an array can be determined as the sum of capacity times SOC for each module of that array). 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 indexes MiPA through MiPQ accordingly for each switch portion 604-PA through 604-PQ.

[0208] During balanced operation, Mi for each switch portion 604 can be set at a value that causes the same or similar amount of net energy over time to be supplied by energy source 206 and / or energy buffer 204 to each array 700. For example, Mi for each switch portion 604 could be the same or similar, and can be set at a level or value that causes the module 108IC to perform a net or time average discharge of energy to the one or more arrays 700-PA through 700-PQ during balanced operation, so as to drain module 108IC at the same rate as other modules 108 in system 100. In some embodiments, Mi for each switch portion604 can be set at a level or value that does not cause a net or time average discharge of energy during balanced operation (causes a net energy discharge of zero). This can be useful if module 108IC has a lower aggregate charge than other modules in the system.

[0209] When an unbalanced condition occurs between arrays 700, then the modulation indexes of system 100 can be adjusted to cause convergence towards a balanced condition or to minimize further divergence. For example, control system 102 can cause module 108IC to discharge more to the array 700 with low charge than the others, and can also cause modules 108-1 through 108-N of that low array 700 to discharge relatively less (e.g., on a time average basis). The relative net energy contributed by module 108IC increases as compared to the modules 108-1 through 108-N of the array 700 being assisted, and also as compared to the amount of net energy module 108IC contributes to the other arrays. This can be accomplished by increasing Mi for the switch portion 604 supplying that low array 700, and by decreasing the modulation indexes of modules 108-1 through 108-N of the low array 700 in a manner that maintains Vout for that low array at the appropriate or required levels, and maintaining the modulation indexes for other switch portions 604 supplying the other higher arrays relatively unchanged (or decreasing them).

[0210] The configuration of module 108IC in FIGs. 10A-10B can be used alone to provide interphase or inter-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 switch portions 604 coupled with different arrays 700 can be combined with a second module 108IC having one switch portion 604 coupled with one array 700 such that the two modules combine to service a system 100 having Q+l arrays 700. Any number of modules 108IC can be combined in this fashion, each coupled with one or more arrays 700 of system 100.

[0211] Furthermore, IC modules 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 IC modules. Specifically, subsystem 1000-1 is configured to supply three- phase power, PA, PB, and PC, to a first load (not shown) by way of system IO 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) by way of system IO ports SIO4, SIO5, and SIO06, respectively. For example, subsystems 1000-1 and 1000-2 can be configured as differentpacks supplying power for different motors of an EV or as different racks supplying power for different microgrids.

[0212] In this embodiment, each module 108IC is coupled with a first array of subsystem 1000-1 (via IO port 1) and a first array of subsystem 1000-2 (via IO port 2), and each module 108IC can be electrically connected with each other module 108IC by way of IO ports 3 and 4, which are coupled with the energy source 206 of each module 108IC as described with respect to module 108C of FIG. 3C. This connection places sources 206 of modules 108IC-1, 108IC-2, and 108IC-3 in parallel, and thus the energy stored and supplied by modules 108IC is pooled together by this parallel arrangement. Other arrangements such as serious connections can also be used. Modules 108IC are housed within a common enclosure of subsystem 1000-1, however, the interconnection modules can be external to the common enclosure and physically located as independent entities between the common enclosures of both subsystems 1000.

[0213] Each module 108IC has a switch unit 604-1 coupled with IO port 1 and a switch unit 604-2 coupled with IO port 2, as described with respect to FIG. 10B. Thus, for balancing between subsystems 1000 (e.g., inter-pack or inter-rack balancing), a particular module 108IC can supply relatively more energy to either or both of the two arrays to which it is connected (e.g., module 108IC-1 can supply to array 700-PA and / or array 700-PD). The control circuitry can monitor relative parameters (e.g., SOC and temperature) of the arrays of the different subsystems and adjust the energy output of the IC modules to compensate for imbalances between arrays or phases of different subsystems in the same manner described herein as compensating for imbalances between two arrays of the same rack or pack. Because all three modules 108IC are in parallel, energy can be efficiently exchanged between any and all arrays of system 100. In this embodiment, each module 108IC supplies two arrays 700, but other configurations can be used including a single IC module for all arrays of system 100 and a configuration with one dedicated IC module for each array 700 (e.g., six IC modules for six arrays, where each IC module has one switch portion 604). In all cases with multiple IC modules, the energy sources can be coupled together in parallel to share energy as described herein.

[0214] In systems with IC modules between phases, interphase 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 the appropriate circumstances under which to performinterphase balancing with neutral point shifting alone, interphase energy injection alone, or a combination of both simultaneously.

[0215] 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 voltages stepped down from source 206). FIG. 10D is a block diagram depicting an example embodiment of a three-phase system 100 with two modules 108IC connected to perform interphase balancing and to supply auxiliary loads 301 and 302. FIG. 10E is a schematic diagram depicting this example embodiment of system 100 with emphasis on modules 108IC-1 and 108IC-2. Here, control circuitry 102 is again implemented as LCD 114 and MCD 112 (not shown). The LCDs 114 can receive monitoring data from modules 108IC (e.g., SOC of ESI, temperature of ESI, Q of ESI, voltage of auxiliary loads 301 and 302, etc.) and can output this and / or other monitoring data to MCD 112 for use in system control as described herein. Each module 108IC can include a switch portion 602 A (or 602B described with respect to FIG. 6C) for each load 302 being supplied by that module, and each switch portion 602 can be controlled to maintain the requisite voltage level for load 302 by LCD 114 either independently or based on control input from MCD 112. In this embodiment, each module 108IC includes a switch portion 602 A connected together to supply the one load 302, although such is not required.

[0216] FIG. 1 OF is a block diagram depicting another example embodiment of a three- phase system 100 configured to supply power to one or more auxiliary loads 301 and 302 with 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 purely auxiliary role and does not actively inject voltage or current into any array 700 of system 100. In this embodiment, module 108IC-3 can be configured like module 108C of FIG. 3B, having a converter 202B,C (FIGs. 6B-6C) with one or more auxiliary switch portions 602 A, but omitting switch portion 601. As such, the 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 for supplying auxiliary loads 301 and 302, and for maintaining charge on the sources 206 of modules 108IC-1 and 108IC-2 through the parallel connection with the source 206 of module 108IC-3.

[0217] 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 through 108-N of the system, although such isnot required. For example, a relatively higher capacity can be desirable in an embodiment where one module 108IC applies energy to multiple arrays 700 (e.g., FIG. 10A) to allow the IC module to discharge at the same rate as the modules of the phase arrays themselves. If the module 108IC is also supplying an auxiliary load, then an even greater capacity may be desired so as to permit the IC module to both supply the auxiliary load and discharge at relatively the same rate as the other modules.Section 7: Examples of Second-Life Energy Sources

[0218] Energy sources 206 can be used in systems 100 described herein for both first-life and second-life applications. A first life of a source 206 is an original application in which source 206 is used. For example, the first life application is the first implementation in which sources 206 are put to use by the first customer of sources 206 after their original manufacture (and not refurbishment). The user of sources 206 in their first life will typically have received sources 206 from the manufacturer, distributor, or original equipment manufacturer (OEM). Battery modules 206 used in a first-life application will typically have the same electrochemistry (e.g., will have the same variant of lithium-ion electrochemistry (e.g., lithium iron phosphate (LFP), lithium nickel manganese cobalt oxides (NMC))) and will have the same nominal voltage and will have a capacity variation across the pack or system that is minimal (e.g., 5% or less). Use of an energy system 100 with batteries 206 in their first life application will result in batteries 206 having a longer lifespan in that first life application, and upon removal from that first life application, the batteries 206 will be more similar in terms of capacity degradation than batteries from a first life application not using the energy system 100.

[0219] As used herein, a “second life” application refers to any application or implementation after the first life application (e.g., a second implementation, third implementation, fourth implementation, etc.) of source 206. A second-life energy source refers to any energy source (e.g., battery or HED capacitor) implemented in that source’s second-life application.

[0220] An example of a first-life application for batteries 206 is within an energy system 100 for an EV. Then, at the end of that life (e.g., after 100,000 miles of driving, or after degradation of the batteries within that battery pack by a threshold amount), the batteries 206 can be removed from the battery pack, optionally subjected to refurbishing and testing, and then implemented in a second life application that can be, e.g., used within a stationary energy storage system (e.g., residential, commercial, or industrial energy buffering, EVcharging station energy buffering, renewable source (e.g., wind, solar, hydroelectric), energy buffering, and the like) or another mobile energy system (e.g., battery pack for an electric car, bus, train, or truck). Similarly, the first life application can be a first stationary application and the second life application can be a stationary or mobile application.

[0221] For the second-life application, sources 206 can be selected and / or utilized by system 100 to minimize (or at least reduce) any differences in initial capacity and nominal voltage. For example, sources 206 having a capacity difference of 5% or more can be included within system 100 and operated to provide energy for a load. In another example, an operator or automated system can select sources 206 for system 100 that have a capacity difference within a threshold amount, e.g., to reduce the initial capacity differences between sources 206 of system 100. If modules 108 are compatible with both the first- and second-life application (e.g., with or without reconfiguration), modules 108 can be selected for the second-life application based on the capacity difference of sources 206 of modules 108.

[0222] System 100 can adjust the utilization of each source 206 individually such that sources 206 within system 100 or packs of system 100 are relatively balanced in terms of SOC or total charge (SOC times capacity) as the pack or system 100 is discharged, even though the sources 206 in system 100 can have widely varying capacities. Similarly, system 100 can maintain balance as the pack or system 100 is charged. Sources 206 can vary not only in terms of capacity but also in nominal voltage, power rating, electrochemical type (e.g., a combination of LFP and NMC batteries), and the like. Thus, system 100 can be used such that all modules 108 within system 100 or each pack of system 100 are second-life energy sources (or such that a combination of first-life and second-life energy sources are used), having various combinations of different characteristics.

[0223] In one example, system 100 can include second-life energy sources 206 (and optionally one or more first-life energy sources 206) having energy capacity variations of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0224] In another example, system 100 can include second-life energy sources 206 (and optionally one or more first-life energy sources 206) having energy capacity per mass density variations of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0225] In another example, system 100 can include second-life energy sources 206 (and optionally one or more first-life energy sources 206) having peak power per mass densityvariations of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0226] In another example, system 100 can include second-life energy sources 206 (and optionally one or more first-life energy sources 206) having nominal voltage variations of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0227] In another example, system 100 can include second-life energy sources 206 (and optionally one or more first-life energy sources 206) having operating voltage range variations of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0228] In another example, system 100 can include second-life energy sources 206 (and optionally one or more first-life energy sources 206) having maximum specified current rise time variations of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0229] In another example, system 100 can include second-life energy sources 206 (and optionally one or more first-life energy sources 206) having specified peak current variations of 2% or more, 5% or more, 10% or more, 15% or more, 20% or more, or 25% or more, 30% or more, 5-30%, 10-30%, and / or 20-30%.

[0230] A variation of X% (e.g., 5% or more, or 5% to 30%) can be met by a variation between the module 108 having the highest value for that parameter and the module 108 having the lowest value for that parameter within system 100. For example, a variation of 5% or more in capacity can be met by a system 100 where the module 108 with the lowest capacity source 206 has a capacity that is 95% or less than that of the module 108 with the highest capacity source 206. For each and every embodiment and parameter disclosed herein, the time at which the system 100 having one or more second life sources satisfies the X% variation condition in that parameter can be at installation of the system 100, at commissioning of the system 100, after replacement of one source 206 with another source 206, after operation of system 100 for 10 hours or more, after operation of system 100 for 100 hours or more, after operation of system 100 for 1000 hours or more, and / or after operation of system 100 for 10,000 hours or more. For example, a variation of capacity of 5% or more can occur after system 100 is operated for 1000 hours, even though the variation in capacity was not present at the time of commissioning. This reflects the capability of theembodiments of system 100 to continue to operate with and account for capacity differences between sources 206 that grow over time of operation.

[0231] In another example, system 100 can include second-life energy sources 206 (and optionally one or more first-life energy sources 206) having variations of electrochemical type (e.g., lithium-ion batteries with non-lithium-ion batteries, or different lithium-ion batteries (e.g., any combination of NMC, LFP, LTO, or other lithium-ion battery types).

[0232] System 100 can include second-life energy sources 206 (and optionally one or more first-life energy sources 206) having any combination of the characteristics provided in the preceding examples.Section 8: Example Embodiments of Charging and Discharging Energy Systems

[0233] Example embodiments pertaining to the charging of an energy system 100 will now be described with reference to FIGs. 11 A-16C. In the described examples, the energy system 100 includes a primary subsystem 1000 and an auxiliary subsystem 2000. Primary subsystem 1000 is implemented as a module-based energy system for generating AC power, e.g., a module-based battery pack that includes multiple connected modules 108. Auxiliary subsystem 2000 is implemented as an energy system for generating DC power, without module converter capabilities, e.g., a conventional battery pack that includes one or more connected battery modules 206. The primary 1000 and auxiliary 2000 subsystems are coupled to each other by a primary converter 420 to facilitate current and power flow between the two subsystems 1000 and 2000. Embodiments of the energy system 100 can be implemented in any of the mobile or stationary applications described herein. Moreover, the charging embodiments of system 100 can be implemented with all aspects of the modulebased energy systems described with reference to FIGs. 1 A-10F unless stated otherwise or logically implausible. For this reason, the many variations contemplated herein will not be repeated with respect to each of the following charging embodiments. Examples of these charging configurations and further configurations are described in IntT. Appl. No.PCT / US2022 / 012205, filed January 12, 2022, and titled Systems, Devices, and Methods for Module-Based Cascaded Energy Systems and IntT. Appl. No. PCT / US2021 / 027154, filed April 13, 2021, and titled Systems, Devices, and Methods for Charging and Discharging Module-Based Cascaded Energy Systems, both of which are incorporated by reference herein in their entirety for all purposes.

[0234] The charging embodiments will be described with reference to the type and quantity of signals available from the charge source to supply charge to the varioussubsystems 1000 and 2000 of system 100. These embodiments fall into three main types: (i) DC charging where the charge source supplies a high-voltage DC charge signal; (ii) singlephase AC charging where the charge source supplies a single high-voltage AC charge signal; and (iii) multiphase AC charging where the charge source supplies two or more high-voltage AC charge signals having different phase angles. For simplicity, the multiphase charging embodiments will be described with respect to a primary subsystem 1000 having three phases although the subject matter is applicable to any modular-based primary subsystem 1000 having two or more arrays that charge and discharge with two or more different phases. The charge source can have various configurations depending on the particular application. For stationary applications, the charge source can be a power grid supplied by a utility or other power provider regardless of energy source type. The charge source can also be a renewable energy source such as an array of solar panels, wind-powered turbines, and the like. For mobile applications, the charge source can also be a grid or renewable energy source, which in many cases is supplied to an EV by way of a charge station that supplies DC, single-phase AC, or multiphase AC power.

[0235] FIGs. 11 A and 1 IB are block diagrams depicting example embodiments of an energy system 100 that includes a (three-phase) primary subsystem 1000 configured to supply three-phase AC power for an AC bus 410. A primary load 101 is coupled to the AC bus 410 to receive AC power. Primary subsystem 1000 also provides supplementary power to a DC bus 415 via primary converter 420. A high-voltage (HV) auxiliary load 303 is coupled to the DC bus 415 to receive DC power. Note, although one primary load 101 and one HV auxiliary load 303 are shown in FIGs. 11 A and 1 IB, energy system 100 can provide power to any number of primary loads 101 and / or HV auxiliary loads 303. For example, the primary load 101 and HV auxiliary load 303 can each include multiple loads connected in parallel or otherwise coupled to the AC 410 and DC 415 buses, respectively.

[0236] In this example embodiment, primary subsystem 1000 includes three arrays 700- PA, 700-PB, and 700-PC that are each configured to output an AC voltage signal having a different phase angle (e.g., 120 degrees apart) onto a respective node NPA, NPB, or Npc of the AC bus 410. Each array 700 includes N modules 108-1 through 108-N connected together to output the AC voltage signal as a superposition of output voltages from each module 108 of that array 700, see FIG. 8B for example. In some embodiments, primary subsystem 1000 also includes interconnection modules 108IC-1 and 108IC-2 configured to supply DC power to low-voltage (LV) auxiliary loads 301 and 302. In these cases, as described in Section 6,interconnection modules 108IC-1 and 108IC-2 can provide inter-array energy balancing and can be configured to output DC voltages to the LV auxiliary loads 301 and 302 by way of ports 3 and 4 connected to a second DC bus 1131, and ports 5 and 6 connected to a third DC bus 1132, respectively.

[0237] Auxiliary subsystem 2000 is configured to supply DC power to the HV auxiliary load 303 by way of the DC bus 415. Auxiliary subsystem 2000 can also receive DC power from primary subsystem 1000 and the various charging embodiments described herein through primary converter 420. The auxiliary subsystem 2000 includes one or more energy sources 206 connected together to output a relatively high DC voltage (e.g., 500V) onto the DC bus 415. For example, auxiliary subsystem 2000 can be a high-voltage battery pack with battery module(s) 206 connected together in different topologies to output the DC voltage with a particular power rating.

[0238] FIGs. 1 IE-11G are block diagrams depicting example embodiments of auxiliary subsystem 2000 having multiple connected energy sources 206. FIG. 1 IE shows an example embodiment of auxiliary subsystem 2000 having a set 800 of N energy sources 206 connected in series such that the DC voltage is a superposition of output voltages of each energy source 206. FIG. 1 IF shows another example embodiment of auxiliary subsystem 2000 having two sets 800-1 and 800-2 of energy sources 206 connected in parallel to increase the amp-hour capacity, where each set 800 includes N energy sources 206 connected in series. FIG. 11G shows yet another example embodiment of auxiliary subsystem 2000 having three sets 800-1, 800-2, and 800-3 of energy sources 206 connected in parallel to further increase the amp-hour capacity, where each set 800 includes N energy sources 206 connected in series. In the embodiments of FIGs. 1 IF- 11G, although it is advantageous for the number of energy sources 206 to be the same in each set 800 within auxiliary subsystem 2000, such is not required and different sets 800 can have differing numbers of energy sources 206, e.g., with different voltage and / or power ratings.

[0239] While auxiliary subsystem 2000 is described herein without module converter capabilities, in other embodiments, auxiliary subsystem 2000 may be a module-based energy system analogous to primary subsystem 1000, but configured for DC power generation (e.g., FIG. 7A). In these cases, auxiliary subsystem 2000 includes multiple modules 108 connected together into an array 700 (or multiple arrays 700, e.g., with parallel connections). This affords auxiliary subsystem 2000 switching capabilities similar to primary subsystem 1000 which allows control system 102 to perform temperature, state of charge (SOC), and / or stateof health (SOH) monitoring and balancing of auxiliary subsystem 2000. However, since auxiliary subsystem 2000 is configured for DC power generation, in an auxiliary role, the absence of integrated converters can be advantageous, e.g., to reduce the complexity of energy system 100, allow more modularity between subsystems of energy system 100, optimize auxiliary power generation and charging, reduce cost, etc.

[0240] Referring back to FIG. 11 A, HV auxiliary load 303 can be an “intermediate” load that has relatively higher voltage, current, and / or power demands than LV auxiliary loads 301 and 302, but less so than primary load 101. For example, primary load 101 can include one or more motors of an EV, HV auxiliary load 303 can include an HVAC system and / or an onboard electrical system of the EV, and LV auxiliary loads 301 and 302 can include all other loads of the EV, e.g., a display, personal electronic devices, control devices (e.g., MCD 112, ECU 104) of a PCD A, etc.

[0241] In some embodiments, HV auxiliary load 303 includes one or more DC auxiliary loads and one or more AC auxiliary loads coupled to DC bus 415, e.g., in parallel. In these cases, each AC auxiliary load can be powered by DC bus 415 using a respective DC-AC power converter coupled therebetween for converting the DC power on DC bus 415 to AC power for the AC auxiliary load. Moreover, in some embodiments, LV auxiliary loads 301 and 302 can be placed in parallel with HV auxiliary load 303 on (or otherwise coupled to) DC bus 415 such that power to auxiliary loads 301, 302, and 303 is managed entirely on DC bus 415 (e.g., FIG. 21B). In these cases, LV auxiliary loads 301 and 302 can be powered by DC bus 415 using respective DC-DC power converters coupled therebetween for converting the DC voltage of DC bus 415 to a suitable voltage level for LV auxiliary loads 301 and 302. Note, when powered by interconnection modules 108IC-1 and 108IC-2 of primary subsystem 1000, such as in the example embodiments shown in FIGs. 11 A and 1 IB, LV auxiliary loads 301 and 302 can also be powered by DC buses 1131 and 1132 using respective DC-DC converters coupled therebetween.

[0242] Primary converter 420 is connected between AC bus 410 and DC bus 415 to transfer power from the three-phase AC side of system 100 to the DC side of system 100. For example, primary converter 420 can include an AC-DC converter (e.g., a HVDC converter) for rectifying one or more AC signals input to ports IO1, IO2, and / or IO3 to a DC signal output to ports IO4 and / or IO5. Primary converter 420 may also include a DC-DC boost converter, a DC-DC buck converter, a DC-DC boost-buck converter, or another type of DC- DC converter to boost or buck the DC signal output by the AC-DC converter to theappropriate DC voltage output by auxiliary subsystem 2000. To perform AC-to-DC conversion, primary converter 420 can be controlled by control system 102 over control lines (not shown). For example, while primary subsystem 1000 is discharging and generating AC signals based on control signals from control system 102, primary converter 420 can receive respective control signals from control system 102 to rectify the AC signals into a DC signal.

[0243] FIGs. 11H-1 IL are schematic diagrams depicting example embodiments of primary converter 420. In the embodiments of FIGs. 11H, 11 J, and 1 IL, primary converter 420 is unidirectional such that power flows from the AC bus 410 to the DC bus 415 but not vice versa. A unidirectional primary converter 420 can be advantageous to isolate auxiliary subsystem 2000 from primary load 101, such that any power flow to primary subsystem 1000 from auxiliary subsystem 2000 occurs through auxiliary converter 430 (if present) which can be managed by interconnection modules 108IC-1 and 108IC-2 both during charging and discharging of primary subsystem 1000. Consequently, auxiliary subsystem 2000 can operate on DC bus 415 continuously to supply and / or receive power while primary subsystem 1000 is charging or discharging. In the embodiments of FIGs. 1 II and 1 IK, primary converter 420 is bidirectional such that power flows between the AC bus 410 and the DC bus 415. A bidirectional primary converter 420 can be advantageous to provide supplemental power to primary load 101 with power generated from auxiliary subsystem 2000 (e.g., during unexpectedly high energy demands) and may also be used by primary subsystem 1000 for charging. For example, control system 102 may be in communication with primary load 101, e.g., via a vehicular ECU 104, and can control primary converter 420 based on the energy demands of primary load 101. In such cases, primary load 101 may output a request for energy, and, responsive to the request, control system 102 can control primary converter 420 to convert DC power on DC bus 415 to AC power for AC bus 410 which can be utilized by primary load 101.

[0244] Referring to FIG. 11H, primary converter 420A includes a (bidirectional) AC-DC converter 422 and a (unidirectional) DC-DC converter 424A. AC-DC converter 422 is configured as a full-bridge converter that includes switches SI through S6 controllable by control system 102 over control lines. Control system 102 can control switches S1-S6 of AC- DC converter 422 (e.g., as a rectifier) to convert a three-phase AC signal received from ports IO 1-IO3 to a DC signal. DC-DC converter 424 A is configured as a DC-DC boost converter that includes an inductor L4, a diode DI, a capacitor C2, and a switch S7 controllable by control system 102 over a control line. Control system 102 can control switch S7 of DC-DCconverter 424A to boost the DC signal generated by AC -DC converter 422 to an appropriate voltage, which is output over ports 104 and 105. In this embodiment, primary converter 420 A includes inductive interface circuity 426 connected between ports IO 1-103 and AC -DC converter 422. To attenuate harmonics to and / or from AC -DC converter 422, interface circuitry 426 includes a respective line filter (inductor-filter) LI, L2, and L3 for each phase input. Primary converter 420A also includes a capacitor Cl (e.g., a DC-link capacitor) coupled between AC -DC converter 422 and DC-DC converter 424A to dampen fluctuations in the DC signal output by AC -DC converter 422.

[0245] The embodiment of primary converter 420B in FIG. 1 II is configured similarly to that of FIG. 11H but with unidirectional DC-DC converter 424 A replaced with a bidirectional DC-DC boost-buck converter 424B. For example, the diode DI of DC-DC converter 424 A can be replaced with a switch S8 connected to control system 102 to facilitate bidirectionality. Control system 102 can then control AC -DC converter 422 (e.g., as an inverter) to convert a DC signal received from DC-DC converter 424B into a three-phase AC signal and output it to ports IO 1-IO3.

[0246] In the embodiment of FIG. 11 J, DC-DC converter 424C is configured as a unidirectional DC-DC buck converter that includes an inductor L4, a diode DI, a capacitor C2, and a switch S7 controllable by control system 102 over a control line. Control system 102 can control switch S7 of DC-DC converter 424C to buck the DC signal generated by AC- DC converter 422 to an appropriate voltage, which is output over ports IO4 and IO5. The embodiment of primary converter 420D in FIG. 1 IK is configured similarly to that of FIG. 11 J but with unidirectional DC-DC converter 424C replaced with a bidirectional DC-DC buck-boost converter 424D. For example, the diode DI of DC-DC converter 424C can be replaced with a switch S8 connected to control system 102 to facilitate bidirectionality.

[0247] FIG. 1 IL is another example embodiment of primary converter 420E implemented in a unidirectional manner. Here, primary converter 420E includes a (unidirectional) AC -DC converter 428, as well as inductive interface circuitry 426 and a capacitor Cl for attenuating high-frequency fluctuations in the input and output voltage signals. AC -DC converter 428 is configured as a full-bridge diode rectifier that includes diodes DI through D6. In this embodiment, no communication with control system 102 is necessary as primary converter 420B can be implemented passively. However, for clarity, the example charging embodiments will be described with respect to a controllable primary converter 420 (e.g., FIGs. 11H-1 IK), which generally provides more flexibility than apassive implementation, e.g., such that primary converter 420 can be bypassed when receiving a charge signal.

[0248] In some embodiments, energy system 100 also includes an auxiliary converter 430 connected to the interconnection modules 108IC and the DC bus 415. In these cases, modules 108IC-1 and 108IC-2 can supply supplemental power to HV auxiliary load 303 and / or charge auxiliary subsystem 2000. For example, auxiliary converter 430 can be connected to ports 3 and 4 of modules 108IC-1 and 108IC-2 via the second DC bus 1131. In other examples, auxiliary converter 430 (or a second auxiliary converter) can be connected to ports 5 and 6 of modules 108IC-1 and 108IC-2 via the third DC bus 1132. The DC voltage output by auxiliary subsystem 2000 is typically higher than the DC voltages output by interconnection modules 108IC such that auxiliary converter 430 boosts the DC power provided by modules 108IC.

[0249] Auxiliary converter 430 can be a unidirectional DC-DC converter such that power flows from DC bus 1131 to DC bus 415. FIG. 1 IM shows an example embodiment of auxiliary converter 430A configured for unidirectional DC-to-DC conversion. In this embodiment, auxiliary converter 430A includes a (bidirectional) DC-AC converter 432, a transformer 436, and a (unidirectional) AC -DC converter 434. When auxiliary converter 430A is implemented in energy system 100, transformer 436 can provide DC-DC isolation between various DC buses and / or lines, e.g., between DC buses 1131 and 415 as shown in FIG. 11 A. DC-AC converter 432 is configured as a full-bridge converter that includes switches SI through S4 controllable by control system 102 over control lines. Control system 102 can control switches S1-S4 of DC-AC converter 432 (e.g., as an inverter) to convert a DC signal received from ports IO1 and IO2 into an AC signal and output it to transformer 436. AC -DC converter 434 is configured as a full-bridge diode rectifier that includes diodes DI through D4. AC -DC converter 434 is passive in this embodiment and can receive a transformed AC signal from transformer 436, and convert it to a DC signal which is output to ports IO3 and IO4. Auxiliary converter 430A also includes a first capacitor Cl connected between ports IO1 and IO2, as well as a second capacitor C2 connected between ports IO3 and IO4. Capacitors Cl and C2 can damp fluctuations in the DC signals received and output by auxiliary converter 430 A, e.g., due to switching of DC-AC converter 432 or other components in the energy system 100.

[0250] Auxiliary converter 430 can also be a bidirectional DC-DC converter such that power flows between the DC buses 1131 and 415. FIG. 1 IN shows an example embodiment of auxiliary converter 430B configured for bidirectional DC-to-DC conversion. Here,auxiliary converter 430B is configured as a dual-active-bridge (DAB) converter, where the unidirectional AC -DC converter 434 of FIG. 1 IM has been replaced with a bidirectional AC- DC converter 438. Similar to DC- AC converter 432, AC-DC converter 438 is configured as a full-bridge converter that includes switches S5 through S8 controllable by control system 102 over control lines. In this embodiment, auxiliary converter 430B can receive, convert, and output DC signals in both directions via the application of appropriate control signals by control system 102. For example, with a bidirectional auxiliary converter 430B, auxiliary subsystem 2000 can supply supplemental power to the LV auxiliary loads 301 and 302, and / or charge the energy sources 206 of interconnection modules 108IC-1 and 108IC-2.

[0251] Energy system 100 includes a switch 1108-PA located between SIO1 and node NPA, a switch 1108-PB located between SIO2 and node NPB, and a switch 1108-PC located between SIO3 and node Npc. Each of switches 1108 are independently controllable by a control signal applied over control lines by control system 102, e.g., MCD 112 (e.g., FIGs. 1A-1C), or an ECU 104 (e.g., FIGs. 1A, IB, ID, and IE).

[0252] In this and other embodiments described herein, primary load 101 can be an electric motor such as a permanent magnet (PM), induction, or switched reluctance motor (SRM). While primary subsystem 1000 here and in many of the following embodiments is a three-phase system having interconnection modules 108IC connected to LV auxiliary loads 301 and 302 and auxiliary converter 430, the charging subject matter can likewise be applied to embodiments having one or more phases, with or without IC modules 108IC, with or without LV auxiliary loads 301 and 302, and with or without auxiliary converter 430. Moreover, for all charging embodiments described herein, connection of HV auxiliary load 303 to DC bus 415 may be maintained to provide continuous power to such electrical systems. In the context of an EV, these can include, e.g., an HVAC system of the EV, an onboard electrical system EV, etc.

[0253] Switches 1108-PA, 1108-PB, and 1108-PC switchably connect three-phase charge signals from ports of a three-phase charge connector (charge port) 1102 over lines 1111 to their respective phase nodes NPA, NPB, and Npc of AC bus 410. The signals are then routed to respective phase arrays 700-PA, 700-PB, and 700-PC of primary subsystem 1000 and respective phase ports IO1, IO2, and IO3 of primary converter 420 which are converted by primary converter 420 to DC signals for delivery to auxiliary subsystem 2000. Charge connector 1102 can be coupled to a charge source 150 by way of the charge source 150’s charge connector 1104 and cable 1106. No neutral connection is necessary for three-phasecharging. Switches 1108 are preferably electro-mechanical switches or relays, but solid-state relays (SSRs) may also be used. For a primary load 101 implemented as a motor, electromechanical switches exhibit high reliability in keeping the motor coils or windings connected to the modular energy sources in case power is lost.

[0254] System 100 also includes monitor circuits 1110-PA, 1110-PB, and 1110-PC that can measure any one or more of the current, voltage, and phase of signals passing through nodes NPA, NPB, and Npc, respectively, and output these measurements over data lines (not shown) to control system 102 for use in controlling modules 108 of primary subsystem 1000 and primary converter 420 during charging and discharging.

[0255] In the embodiment of FIG. 11 A, switches 1108 are each two-conductive position(TCP) switches (e.g., single pole double throw (SPDT) switches). When TCP switches 1108 are in position 1, AC bus 410 is connected to primary load 101 and connector 1102 is uncoupled and not energized. TCP switches 1108 default to position 1 as the normal position and assume this position when no control signal is applied. In case of a power loss or occurrence where TCP switches 1108 are disconnected from the control signal, they can revert to position 1 so as not to leave the primary load 101 unconnected. If a control signal (e.g., a common signal) is applied, then TCP switches 1108 move to position 2 and couple connector 1102 to AC bus 410. When in position 2, system 100 can be charged through connector 1102. Application of the control signal can happen automatically when system 100 detects physical coupling of charge source connector 1104 to system connector 1102, or detects the presence of multiphase voltage at connector 1102. Application of the control signal may also be conditioned on the primary load 101 being off. Removal of the control signal, such as after detection of decoupling of connector 1104 or absence of multiphase charge voltage at connector 1102, causes TCP switches 1108 to return to position 1.

[0256] In the embodiment of FIG. 1 IB, switches 1108 are on / off switches having an open state and a closed state (e.g., single pole single throw (SPST) switches) that are again controllable by application of a control signal (not shown). AC bus 410 is constantly connected to connector 1102 and thus primary 1000 and auxiliary 2000 subsystems can be constantly energized, so connector 1102 is configured such that its internal conductors are isolated from user contact. For example, the conductors may be housed deep within the charging receptacle of connector 1102. The design of connector 1102 is preferably sufficient to prevent user contact (e.g., shock or short) such that connector 1102 can be energized even when primary load 101 is operating. The closed position is the default position of switches 1108 in this embodiment to keep system 100 connected to primary load 101, as damage toload 101, damage to converters 202 of modules 108, and / or damage to primary converter 420 can occur if switches 1108 open during operation of load 101. Application of the control signal causes switches 1108 to open, which disconnects system 100 from load 101 and permits charging through connector 1102. Although three on / off switches 1108 are shown here, in embodiments with a closed coil motor 1100 implemented as primary load 101, one of the on / off switches 1108 can be omitted, e.g., only two of the three on / off switches 1108 can be present (for any two of phases PA, PB, or PC), as current will not pass through motor 1100 when two of the three coils are electrically disconnected. The third coil can be left electrically connected to system 100 during charging.

[0257] FIG. 11C is a flow diagram depicting an example embodiment of a method 1150 for charging that is applicable to the embodiments of FIGs. 11 A-l IB, as well as other embodiments described herein.

[0258] At 1152, system 100 detects connection of charge source 150 to connector 1102. As stated herein, this can occur by control system 102 detecting physical contact of charge source connector 1104 to system connector 1102, or by system 100 sensing the charge signal voltage with sensors in connector 1102. At 1154, after detecting the connection of charge source 150, switches 1108 can be switched from discharge positions to charge positions (e.g., position 2 with respect to TCP switches 1108 in FIG. 11 A, or an open state with respect to on / off switches 1108 in FIG. 1 IB).

[0259] At 1156, the charge signals supplied by charge source 150 are monitored by monitor circuits 1110 and this information is output to control system 102. FIG. 1 ID is a plot depicting three-phase charge signals 1112-PA, 1112-PB, and 1112-PC. At 1158, control system 102 outputs control signals to each module 108 of primary subsystem 1000 that causes converters 202 of each module 108 to switch to appropriately charge. Control system 102 also outputs control signals to primary converter 420 to appropriately rectify (and boost or buck) the charge signals for DC charging of auxiliary subsystem 2000. Steps 1156 and 1158 are performed concurrently to provide control system 102 with a continuous assessment of the voltage, current, and / or phase of the charge signals while adjusting the switching scheme for each module 108 and primary converter 420 accordingly.

[0260] When switching modules 108 at step 1158, control system 102 (e.g., MCD 112, LCDs 114) generates switching signals for the converter 202 of each module 108 as described in Sections 3 and 5. Each converter 202 can be switched between a first state that presents +VDCL at the module IO ports 1 and 2, a second state that presents -VDCL at ports 1 and 2, and a third state where the module 108 is bypassed (shorted) and presents zero voltageat ports 1 and 2. Switching can be controlled such that each energy source 206 of each module 108 can be charged based on the direction of the current through each array 700.

[0261] Control system 102 can be programmed to control switching of each module 108 to minimize distortion and displacement within the array(s) 700 of each phase. This can be achieved by targeting a power factor (PF) at or near one (unity), according to Equation (1): Ilrms\ (1)PF = ( — - ) cos 6,Irms )

[0262] where Ilrms is the root mean square value of the fundamental component of the current within the array 700 of the particular phase (e.g., array 700-PA), Irms is the root mean square value of the total of all significant harmonics of current (I1+I2+I3 . . .) of the particular phase, and 0 is the phase angle between voltage and current of the particular phase. To achieve a PF at or near one, control system 102 can control switching such that the sum of the currents of each phase (e.g., as measured at nodes NPA, NPB, and Npc) is zero or close to zero (e.g., within a threshold) at all times, and the displacement (0) between current and voltage of each phase is zero or close to zero (e.g., within a threshold) at all times.

[0263] Each module 108 can be charged equally until a limit or threshold is reached for that individual module 108. For example, all modules 108 may be charged equally (e.g., receive the same aggregate current over time) until an individual module 108 reaches a charge threshold (e.g., 80% or 90% of capacity) at which time charging of that module 108 is slowed until all modules 108 reach a balanced or substantially balanced SOC state, at which time the modules 108 are charged equally until fully or adequately charged.

[0264] Alternatively, modules 108 with relatively lesser SOC levels can receive relatively more charging at the outset until primary subsystem 1000 reaches a relatively balanced SOC state, at which time all modules 108 can be charged in a manner such that the primary subsystem 1000 has a relatively balanced SOC state at all times (e.g., all fully functional modules 108 are within 1% of the others in terms of SOC). This approach has the advantage that, if charging is stopped prior to the primary subsystem 1000 reaching capacity, then primary subsystem 1000 will exit the charging process in a relatively balanced state.

[0265] Referring back to FIG. 11C, method 1150 can continue until 1160 when modules 108 have been fully (or adequately) charged or system 100 detects the disconnection of charge source 150, at which point switches 1108 can be transitioned from their charge positions back to default positions of the discharge state (e.g., position 1 with respect to TCP switches 1108 in FIG. 11 A, or a closed position with respect to on / off switches 1108 in FIG. 11B).

[0266] In the embodiments described herein, control system 102 can control switching by generation of switching signals for each module 108 according to a PWM technique, such as those described in Section 5, utilizing an incoming AC charge signal (or representation thereof) for each phase as the reference waveform for the respective array 700, or a different reference in the case of DC charging. In a similar vein, control system 102 can also use a PWM technique to switch primary converter 420 when rectifying the charge signals. Modulation indexes for the switching circuitry of each module 108 can be adjusted to maintain the power factor at or near one by selectively charging and discharging each module 108 for various lengths of time. Charging can also be performed while maintaining or targeting a balanced condition in one or more operating characteristics of primary subsystem 1000 as described in Section 5. Modulation indexes (Mi) can also be adjusted to perform charging while targeting a relatively balanced temperature across all modules 108, and emphasizing charging for energy sources 206 having the relatively lowest SOC by assigning those modules 108 the relatively highest modulation indexes.

[0267] Furthermore, for electrochemical battery sources 206, the length of the charge pulses applied to sources 206 by converter 202 can be maintained to have a certain length, e.g., less than 5 milliseconds, to promote the occurrence of the electrochemical storage reaction in the cells without the occurrence of significant side reactions that can lead to degradation. Such pulses can be applied at high C rates (e.g., 5C-15C and greater) to enable fast charging of the sources 206. Examples of such techniques that can be used with all embodiments herein are described in Int’l Appl. No. PCT / US20 / 35437, titled Advanced Battery Charging on Modular Levels of Energy Storage Systems, which is incorporated by reference herein for all purposes.

[0268] In the example embodiments of FIGs. 11 A and 1 IB, interconnection modules 108IC-1 and 108IC-2 are connected to each other and also interconnected between arrays 700 of different phases. During charging, the switch portions 604 (for example, see FIG. 10E) of modules 108IC can be continually switched such that current flows either through S7 or S8 at a 50-50 duty cycle. The energy sources 206 of modules 108IC can be charged by adjusting the duty cycle of each switch portion 604 to a state where aggregate current over time through each portion 604 causes sources 206 of those modules 108IC to charge. Alternatively, the switch portions 604 of modules 108IC can be switched only on an as- needed basis for directing current through modules 108IC, e.g., to steer current while charging the source 206 of modules 108IC-1 or 108IC-2, or to steer current without charging the source 206. Switching of modules 108IC can also be used to minimize distortion anddisplacement within each array 700. For all embodiments having LV auxiliary loads 301 and 302 and / or auxiliary converter 430 connected to DC buses 1131 and / or 1132, during charging, control system 102 can continue to regulate the voltage for LV auxiliary load 302 through switch portions 602 A (FIG. 10E), and thus power can be maintained for LV auxiliary loads 301 and 302, as well as power through auxiliary converter 430, if desired. In the context of an EV, this can maintain power to the display, auxiliary devices, etc.

[0269] While charging has been described with reference to a PWM control technique, in alternative embodiments a hysteresis technique can be used. Other custom techniques based on PWM or hysteresis, or altogether different from PWM and hysteresis (e.g., ad hoc techniques), may also be used.Section 9: Example Embodiments of DC and Single-phase Charging of Energy Systems with Primary Load Bypass

[0270] Multiphase configurations of energy system 100 can also be charged with a DC or single-phase AC charge source. FIG. 12A is a block diagram depicting an example embodiment of an energy system 100 configured similarly to the embodiment of FIG. 11 A but with routing circuitry 1200 that permits DC and / or single-phase AC charging capability in addition to multiphase AC charging capability, where all charging can occur in a manner that bypasses primary load 101. Routing circuitry 1200 can be coupled between multiphase charge connector 1102 and three-phase charge lines 1111. Routing circuitry 1200 can be coupled with at least one connector (charge port) 1202 that can receive DC charging signals (DC+ and DC-) and / or AC charging signals (AC line (L) and neutral (N)) over lines 1211. These connections can be shared as shown in FIG. 12A or can be separate such that different conductors of lines 1211 are utilized for DC and single-phase AC. In the embodiments described herein, connector 1202, whether configured for DC only, single-phase AC only, or both, can be a separate and discrete connector from that of three-phase charge connector 1102, or connectors 1102 and 1202 can be combined in a single location (e.g., on an EV) as described with respect to FIG. 12F. If combined in a single location, the conductors for multiphase AC charging, single-phase AC charging, and DC charging can be shared as described herein. Various different configurations and types of circuitry can be used for routing circuitry 1200 depending on the type of charging signal being routed (DC or AC), and whether the embodiment provides for selective disconnection of the charge connectors 1102 and 1202 from system 100. Various example embodiments of routing circuitry 1200 are described in greater detail herein.

[0271] Switches 1108 can be part of a single switching assembly 1250 that is configured to conduct the high currents required during charge and discharge phases. Assembly 1250 may be configured as a discrete single device or housing. Assembly 1250 can have one or more inputs to receive switching control signals from control system 102. In some embodiments, monitor circuits 1110 can be integrated into assembly 1250, and the control signals to circuits 1110, as well as the data outputs from circuits 1110, can be routed through IO ports of assembly 1250 to control system 102. Example embodiments of assembly 1250 are described further in Section 18 with respect to a power and control distribution assembly (PCDA) 1250 in FIGs. 21A-21G.

[0272] FIG. 12B is a schematic diagram depicting an example embodiment of routing circuitry 1200 configured with solid-state (or semiconductor) relay (SSR) circuits 1221 and to provide DC and single-phase AC charging capability by way of connector 1202 in addition to three-phase AC charging by way of three-phase lines 1111 and connector 1102. Connector 1202 can be connected to either a single-phase charging cable in turn connected to a singlephase charge source, or can be connected to a DC charging cable in turn connected to a DC charge source. Routing circuitry 1200 has IO ports 1201-1 and 1201-2 connected to connector 1202, and IO ports 1204-PA, 1204-PB, and 1204-PC that can be connected to charge lines 1111 for each phase PA, PB, and PC, respectively. As shown in FIG. 12H, routing circuitry 1200 can also be configured with an energy buffer 204, in this case a capacitor CRC, to dampen high-frequency fluctuations in DC and single-phase AC charge signals. For DC charging and single-phase AC charging, routing circuitry 1200 can be controlled to selectively output each of the charge signals on inputs 1201 (either DC+ and DC- charge signals or AC(L) and AC(N) charge signals) to one or more of the three different outputs 1204. Routing circuitry 1200 also includes one or more IO ports 1206-1 through 1206-4 for control signals CS1 through CS4, respectively, that control the routing of each input 1201 to each output 1204. Control signals CS1-CS4 can be generated and provided by control system 102 over control lines (not shown).

[0273] The use of SSRs isolates energy system 100 from the DC or AC charger, which means additional isolation circuitry (e.g., high-frequency transformer and inverters) in the charger can be removed or omitted altogether. This can simplify the charger implementation and substantially reduce cost. In this embodiment, there are four SSR circuits indicated as 1221-1, 1221-2, 1221-3, and 1221-4, each having a control port 1206-1, 1206-2, 1206-3, and 1206-4 respectively. Each SSR circuit 1221 can be selectively placed in a bidirectional current conducting (closed) state or a non-conductive (open) state by application of a controlsignal (CS1, CS2, CS3, and CS4, respectively) from control system 102 to the control ports 1206-1, 1206-2, 1206-3, and 1206-4. For single-phase AC charging, routing circuitry 1200 can selectively output each of the AC(L) and AC(N) signals at IO ports 1201-1 and 1201-2, respectively, to one or more of the three different IO ports 1204-PA, 1204-PB, and 1204-PC each connected to different phase lines 1111 from three-phase charge connector 1102, which are in turn connected to different phase lines of AC bus 410. The AC(L) and AC(N) signals are then routed to respective arrays 700-PA, 700-PB, and 700-PC for charging primary subsystem 1000 as well as respective phase inputs IO1, IO2, and IO3 of primary converter 420 which are converted to DC at the appropriate DC voltage for charging auxiliary subsystem 2000 over DC bus 415. For DC charging, routing circuitry 1200 can selectively output each of the DC+ and DC- signals at inputs 1201 to one or more of the three IO ports 1204 for delivery to arrays 700 of primary subsystem 1000 and primary converter 420. The DC+ and DC- signals pass over the rectifier of primary converter 420, boosted or bucked to the appropriate DC voltage, and thereafter placed on the DC bus 415 for provision to auxiliary subsystem 2000. Selective routing is controlled by control signals CS1-CS4 supplied by control system 102 and applied to one or more control ports 1206-1 through 1206-4.

[0274] Example embodiments of SSR circuits 1221 are described with respect to the schematic views of FIGs. 12C, 12D, and 12E. In FIG. 12C, SSR circuit 1221 is a triac that is controllable by a control signal input to control port 1206. When the triac is enabled with the control signal, it is placed in the closed state and current can pass bidirectionally through the triac. When unenabled, no current passes through the triac. Alternatively, SSR circuit 1221 can be a thyristor and implemented in a unidirectional manner. In this case, thyristors can provide DC charging but not single-phase AC charging due to the unidirectionality. Nevertheless, thyristors can be advantageous in facilitating cost reduction over triacs.

[0275] In FIG. 12D, SSR circuit 1221 includes two insulated gate bipolar (IGBT) transistors QI and Q2 connected in series with emitter nodes connected together and collector nodes forming input / output ports to the circuit 1221. Each IGBT has a body diode (DI, D2) oriented in opposite current-carrying directions to block passing currents when QI and Q2 are inactivated. Application of a control signal to port 1206 will bias the gate node of transistors QI and Q2 to either activate the IGBTs and allow current to flow through circuit 1221 in the closed state, or inactivate the IGBTs to block current from flowing through circuit 1221 in the open state. Other semiconductor devices can be used instead of an IGBT, such as a MOSFET or a GaN device.

[0276] In FIG. 12E, SSR circuit 1221 includes an IGBT transistor Q3 and a bridge diode circuit having four diodes D3, D4, D5, and D6. Q3 is positioned within the bridge diode circuit to permit current to flow through SSR circuit 1221 when Q3 is activated by the application of a control signal to port 1206. For example, when Q3 is inactivated, circuit 1221 is in the open state and no current can flow. When Q3 is activated, circuit 1221 is in the closed state, and current can flow from left to right through D3, Q3, and D6, and from right to left through D5, Q3, and D4. Any combination of the embodiments of SSR circuits 1221 in FIGs. 12C-12E can be used in the routing circuitry 1200 embodiments described herein. Other SSR circuit designs can be used as well.

[0277] DC and single-phase AC charging of primary 1000 and auxiliary 2000 subsystems of system 100 are described below using routing circuitry 1200. Particularly, control system 102 manipulates SSR circuits 1221 of routing circuitry 1200 to isolate pairs of arrays 700 of primary subsystem 1000, such that corresponding charge signals from the external charge source (either DC+ and DC- signals, or AC(L) and AC(N) signals) are routed to respective pairs of nodes of AC bus 410, e.g., NPA and NPB, NPA and Npc, or NPB and Npc. Primary subsystem 1000 receives the charge signals from AC bus 410 at the particular pair of arrays 700 which are used for charging of its modules 108. Similarly, primary converter 420 receives the charge signals from AC bus 410 at a corresponding pair of phase ports, e.g., IO1 and IO2, IO1 and IO3, or IO2 and IO3, which are used for charging auxiliary subsystem 2000.

[0278] To charge auxiliary subsystem 2000 concurrently with primary subsystem 1000, control system 102 controls primary converter 420 to convert the externally sourced charge signals received from AC bus 410 into DC charge signals (e.g., boosted or bucked), which are output onto DC bus 415 through ports IO4 and IO5. Using the embodiment of primary converter 420A in FIG. 11H as an example, when DC+ and DC- signals are received at ports IO1 and IO2, control system 102 can turn switches SI and S4 on and switches S2, S3, and S7 off such that DC+ and DC- signals are placed on ports IO4 and IO5. Alternatively, control system 102 can control switch S7 to boost the DC charge signals. As another example, when AC(L) and AC(N) charge signals are received at ports IO1 and IO2, control system 102 can apply control signals to switches S1-S4 to rectify the AC signals into a DC signal, which can be subsequently boosted by appropriate control of switch S7 and output at ports IO4 and IO5. A similar procedure holds when charge signals are received by primary converter 420A at different pairs of ports, e.g., IO1 and IO3, or IO2 and IO3.

[0279] During the charge phase, each of switches 1108 can be transitioned to charge position 2, or alternatively, only the switches 1108 associated with the arrays 700 being charged can be switched to position 2, with the switch 1108 of any array 700 not being charged left in position 1. Thus some commutation of switches 1108 during the charge phase may be necessary.

[0280] DC Charging Example 1 :

[0281] To DC charge modules 108 of arrays 700-PA and 700-PB (including modules 108IC-1 and 108IC-2, which are connected in parallel), control system 102 places circuits 1221-1 and 1221-3 in conducting states by way of application of control signals CS1 and CS3, respectively, and places circuits 1221-2 and 1221-4 in non-conducting states by way of application of control signals CS2 and CS4, respectively. Current passes from port 1201-1 through circuit 1221-1 to IO port 1204-PA, which is connected to the PA line 1111 from three-phase charge connector 1102. The current bypasses primary load 101, passes through switch 1108-PA, and through array 700-PA. Each module 108-1 through 108-N of array 700- PA can be selectively charged in a continuous or pulsed form as described in Section 3. Current passes through module 108IC-1 (e.g., switches S7 of portions 604-PA and 604-PB, or switches S8 of portions 604-PA and 604-PB, as described with respect to FIG. 10E) and through array 700-PB, and each module 108-1 through 108-N of array 700-PB can also be selectively charged in a continuous or pulsed form taking into account opposite current direction. Current passes through switch 1108-PB, into routing circuitry 1200 via IO port 1204-PB, then through circuit 1221-3, and out through DC- port 1201-2.

[0282] DC Charging Example 2:

[0283] To DC charge modules 108 of arrays 700-PB and 700-PC (including modules 108IC-1 and 108IC-2), control system 102 places circuits 1221-2 and 1221-4 in conducting states by way of application of control signals CS2 and CS4, respectively, and places circuits 1221-1 and 1221-3 in non-conducting states by way of application of control signals CS1 and CS3, respectively. Current passes from the DC+ port 1201-1 through circuit 1221-2 to IO port 1204-PB, which is connected to the PB line 1111 from three-phase charge connector 1102. The current bypasses primary load 101, passes through switch 1108-PB, and through array 700-PB. Each module 108-1 through 108-N of array 700-PB can be selectively charged in a continuous or pulsed form as described in Section 3. Current passes through module 108IC-1 then module 108IC-2 (e.g., using switches S7 together, or S8 together, of portions 604-PB and 604-PC of FIG. 10E), and through array 700-PC, and each module 108-1 through 108-N of array 700-PC can also be selectively charged in a continuous or pulsed form takinginto account opposite current direction. Current passes through switch 1108-PC and into routing circuitry 1200 through IO port 1204-PC, then through circuit 1221-4, and exits DC- port 1201-2.

[0284] DC Charging Example 3 :

[0285] To DC charge modules 108 of arrays 700-PA and 700-PC (including modules 108IC-1 and 108IC-2), control system 102 places circuits 1221-1 and 1221-4 in conducting states by way of control signals CS1 and CS4, respectively, and places circuits 1221-2 and 1221-3 in non-conducting states by way of control signals CS2 and CS3, respectively. Current passes from DC+ port 1201-1 through circuit 1221-1 to IO port 1204-PA. The current bypasses primary load 101, passes through switch 1108-PA, and through array 700- PA. Each module 108-1 through 108-N of array 700-PA can be selectively charged in a continuous or pulsed form as described in Section 3. Current passes through module 108IC-1, then module 108IC-2 (e.g., using switches S7 together, or S8 together, of portions 604-PA and 604-PC of FIG. 10E), and through array 700-PC, and each module 108-1 through 108-N of array 700-PC can also be selectively charged in a continuous or pulsed form taking into account opposite current direction. Current passes through switch 1108-PC and into routing circuitry 1200 through IO port 1204-PC, then through circuit 1221-4, and exits through DC- port 1201-2.

[0286] In each of the above three DC charging examples, interconnection modules 108IC-1 and 108IC-2 can charge their energy source(s) 206 by routing the incoming current from arrays 700 through the source(s) 206 by the appropriate combinations of switches in portions 604-PA, 604-PB, and 604-PC prior to outputting the current from the modules 108IC. In embodiments including auxiliary converter 430, the energy source(s) 206 may also receive from (or output to) DC bus 415 during charging, in which case modules 108IC-1 and 108IC-2 can combine the received currents using the appropriate combinations of switches in portions 604-PA, 604-PB, and 604-PC and / or appropriate control of auxiliary converter 430.

[0287] The above three DC charging examples can also be cycled to effectively perform DC pulse charging of primary subsystem 1000’s arrays 700, such that module converters 202 do not require individual switching to enable pulse charging. In these cases, converters 202 can connect energy source(s) 206 of each module 108 of an array 700 such that the charge source voltage is divided across modules 108-1 through 108-N, thus, each module 108 of the array 700 exhibits the same effective DC charge signal in a pulsed form. Further, control system 102 can bypass any (passive) energy buffers 204 (e.g., using active energy buffers204 in FIGs. 5D-5I) that may be implemented in modules 108 of the array 700 to prevent smoothing or rounding of the pulsed DC charge signals.

[0288] For example, control system 102 can perform the following steps to implement DC pulse charging at a 66% duty cycle for a pulse period of 1.5 ms: (i) control system 102 routes DC+ and DC- charge signals to arrays 700-PA and 700-PB for 1 ms (see DC Charging Example 1), (ii) control system 102 swaps the DC+ and DC- charge signals to arrays 700-PB and 700-PC for 1 ms (see DC Charging Example 2), and (iii) control system 102 then swaps the DC+ and DC- charge signals to arrays 700-PA and 700-PC for 1 ms (see DC Charging Example 3). Control system 102 can repeat this procedure until each array 700 is adequately charged and the charge port 1202 still sees a continuous (or nearly continuous) current draw. Moreover, control system 102 can simultaneously cycle switches of primary converter 420 at the same duty cycle so that the DC+ and DC- charge signals are placed on DC bus 415 in a continuous manner. In these and other charging embodiments, routing circuity 1200 configured with an in-built energy buffer 204 (e.g., FIG. 12H) can be used to damp fluctuations in the current that may occur due to cycled switching of SSR circuits 1221. This further stabilizes the current draw from charge port 1202.

[0289] Although the examples of DC pulse charging are described above with energy buffers 204 of modules 108 bypassed, in other embodiments, energy buffers 204 may also be functional during DC pulse charging. In these cases, control system 102 can maintain the connection (e.g., FIGs. 5A-5C), vary the connection (e.g., FIGs. 5D-5I), and / or vary filter parameters (e.g., FIGs. 5H-5J) of one or more module 108’s energy buffers 204 during DC pulse charging. This can enable a few other desirable effects. For example, control system 102 can actively control the filter parameters of an energy buffer 204 to intentionally cause smoothing and rounding of a pulsed DC charge signal, providing a charge profile similar to a sinusoidal wave. As another example, if the energy source(s) 206 of a particular module 108 have a high SOC, control system 102 can reconnect a disconnected energy buffer 204 to approximate constant DC charging.

[0290] Single-phase AC charging when the AC signal is positive can be performed in the same manner, with SSR circuits 1221 in the same states, as described above for the DC charging examples. Current flow is in the opposite direction when the single-phase AC charge signal is in the negative half of the cycle.

[0291] AC Charging Example 1 :

[0292] To charge modules 108 of arrays 700-PA and 700-PB (including modules 108IC- 1 and 108IC-2) when the AC signal is negative, control system 102 places circuit 1221-1 andcircuit 1221-3 in conducting states by way of application of control signals CS1 and CS3, respectively, and places circuits 1221-2 and 1221-4 in non-conducting states by way of application of control signals CS2 and CS4, respectively. Current passes from AC(N) port 1201-2 through circuit 1221-3 to IO port 1204-PB, and from there bypasses primary load 101, passes through switch 1108-PB, and through array 700-PB. Each module 108-1 through 108-N of array 700-PB can be selectively charged in a continuous or pulsed form as described in Section 3. Current passes through module 108IC-1 (e.g., using switches S7 together, or S8 together, of portions 604-PA and 604-PB of FIG. 10E) and through array 700- PA, and each module 108-1 through 108-N of array 700-PA can also be selectively charged in a continuous or pulsed form taking into account opposite current direction. Current passes through switch 1108-PA, into routing circuitry 1200 via IO port 1204-PA, then through circuit 1221-1, and out through AC line (L) port 1201-1.

[0293] AC Charging Example 2:

[0294] To charge modules 108 of arrays 700-PB and 700-PC (including modules 108IC-1 and 108IC-2) when the AC signal is negative, control system 102 places circuits 1221-2 and 1221-4 in conducting states by way of control signals CS2 and CS4, respectively, and places circuit 1221-1 and 1221-3 in non-conducting states by way of control signals CS1 and CS3, respectively. Current passes from AC(N) port 1201-2 through circuit 1221-4 to IO port 1204- PC, bypasses primary load 101, passes through switch 1108-PC, and through array 700-PC. Each module 108-1 through 108-N of array 700-PC can be selectively charged in a continuous or pulsed form as described in Section 3. Current passes through module 108IC-2 and then module 108IC-2 (e.g., using switches S7 together, or S8 together, of portions 604- PB and 604-PC of FIG. 10E), and through array 700-PB, and each module 108-1 through 108-N of array 700-PB can also be selectively charged in a continuous or pulsed form taking into account opposite current direction. Current passes through switch 1108-PB and into routing circuitry 1200 through IO port 1204-PB, then through circuit 1221-2, and exits through AC(L) port 1201-1.

[0295] AC Charging Example 3 :

[0296] To charge modules 108 of arrays 700-PA and 700-PC (including modules 108IC- 1 and 108IC-2) when the AC signal is negative, control system 102 places circuits 1221-1 and 1221-4 in conducting states by way of control signals CS1 and CS4, respectively, and places circuits 1221-2 and 1221-3 in non-conducting states by way of control signals CS2 and CS3, respectively. Current passes from AC(N) port 1201-2 through circuit 1221-4 to IO port 1204-PC. The current bypasses primary load 101, passes through switch 1108-PC, andthrough array 700-PA. Each module 108-1 through 108-N of array 700-PC can be selectively charged in a continuous or pulsed form as described in Section 3. Current passes through module 108IC-2 and then module 108IC-1 (e.g., using switches S7 together, or S8 together, of portions 604-PA and 604-PC of FIG. 10E), and through array 700-PA, and each module 108-1 through 108-N of array 700-PA can also be selectively charged in a continuous or pulsed form taking into account opposite current direction. Current passes through switch 1108-PA and into routing circuitry 1200 through IO port 1204-PA, then through circuit 1221- 1, and exits through AC(L) port 1201-1.

[0297] FIG. 12F is a block diagram depicting an example embodiment of system 100 similar to that of FIG. 12 A except with a shared charge port 1102 / 1202 having three conductive IOs for use in DC, single-phase AC, and three-phase AC charging. FIG. 12G is a schematic view depicting an example embodiment of routing circuitry 1200 configured for use with the shared charge port 1102 / 1202 depicted in FIG. 12F. Here, SSR circuit 1221-4 is coupled between the charger sides of circuits 1221-1 and 1221-2, and SSR circuit 1221-5 is coupled between the charger sides of circuits 1221-2 and 1221-3. To perform three-phase charging, SSR circuits 1221-1, 1221-2, and 1221-3 are closed and SSR circuits 1221-4, and 1221-5 are opened. To perform DC and single-phase AC charging of arrays 700-PA and 700- PB, circuits 1221-1, 1221-3, and 1221-5 are closed and circuits 1221-2 and 1221-4 are opened. To perform DC and single-phase AC charging of arrays 700-PB and 700-PC, circuits 1221-1, 1221-3, and 1221-4 are closed and circuits 1221-2 and 1221-5 are opened. To perform DC and single-phase AC charging of arrays 700-PA and 700-PC, circuits 1221-1 and 1221-3 are closed and circuits 1221-2, 1221-4, and 1221-5 are opened.

[0298] Use of the TCP switches 1108 for energy system 100, as shown in FIGs. 11 A, 12A, and 12F, results in automatic disconnection and isolation of charge connectors 1102 and 1202 when TCP switches 1108 are in the discharge position 1. Similarly, primary load 101 is automatically disconnected from AC bus 410 and isolated when TCP switches 1108 are in charge position 2. When using on / off switches 1108, like in the embodiment of FIG. 1 IB, primary load 101 is disconnected from AC bus 410 when on / off switches 1108 are opened in the charge state. Charge connectors(s) 1102, 1202 remain connected when on / off switches 1108 are closed and primary load 101 is connected to AC bus 410 for the discharge state. FIGs. 13A-13D depict example embodiments using on / off switches 1108 and having the capability to selectively disconnect charge connectors 1102, 1202 while primary load 101 is connected to AC bus 410 and primary subsystem 1000 is in the discharge state.

[0299] FIG. 13 A is a block diagram depicting system 100 configured with on / off switches 1108, similar to that of FIG. 1 IB, but with routing circuitry 1200 that permits DC and / or single-phase AC charging in addition to multiphase AC charging while bypassing primary load 101. The conductors of connectors 1102 and 1202 are in a shared configuration 1102 / 1202. Like the embodiments of FIG. 12A and 12F, in this embodiment, on / off switches 1108 can be placed in a unified switch assembly device 1250. The embodiment of FIG. 13 A can be used with routing circuitry 1200 configured as shown in FIG. 12G.

[0300] FIG. 13B is a block diagram depicting an example embodiment similar to that depicted in FIG. 13A except for separate charge connectors 1102 and 1202. The embodiment of FIG. 13B can be used with routing circuitry 1200 configured as described with reference to FIG. 13C, which is a schematic diagram depicting an example embodiment of routing circuitry 1200 similar to the embodiment of FIG. 12B but having additional SSR circuits 1221-5, 1221-6, and 1221-7 (collectively referred to as switches 1331) configured to selectively disconnect lines 1111-PA, 1111-PB, and 1111-PC connected between respective AC bus lines 410-PA, 410-PB, and 410-PC and connector 1102. Switches 1331 can alternatively be electromechanical relays. Each of switches 1331 can be controlled with control signals received at IO ports 1206. (Control connections not shown.) Control system 102 can generate and output the control signals to switches 1331. While on / off switches 1108 are configured to default to a closed position to keep primary load 101 connected to system 100, switches 1331 are configured to default to an open state to keep charge connectors 1102 and 1202 disconnected from system 100. For three-phase AC charging, switches 1331 are placed in the closed state, while SSR circuits 1221-1, 1221-2, 1221-3, and 1221-4 are placed in the open state. For DC and single-phase AC charging, switches 1331 are placed in the open state and SSR circuits 1221-1 through 1221-4 can be operated similarly to the embodiment described with respect to FIG. 12B.

[0301] FIG. 13D is a block diagram depicting an example embodiment similar to that of FIG. 13B, but with switches 1331 moved from routing circuitry 1200 (as depicted in FIG. 13C) to switch assembly 1250. Within switch assembly 1250, switches 1331 can be SSR circuits 1221, electromechanical relays, or otherwise.

[0302] Different approaches can be used to charge each pair of primary subsystem 1000’s arrays 700 while simultaneously charging auxiliary subsystem 2000. In one example embodiment, when charging arrays 700-PA and 700-PB, charging can be performed until both arrays 700-PA and 700-PB have reached a first threshold (e.g., 40% to 50%). Then when charging arrays 700-PB and 700-PC, charging can be performed until array 700-PB hasreached a second, higher threshold (e.g., 80% to 100%) and array 700-PC has reached the first threshold (e.g., 40% to 50%). Then when charging arrays 700-PA and 700-PC, charging can be performed until both arrays 700-PA and 700-PC reach the second threshold (e.g., 80% to 100%). In another example embodiment, routing circuitry 1200, switches 1108, and modules 108 of each array 700 can be controlled and cycled to charge up all arrays 700 in relative unison (e.g., array 700-PA modules are charged one or a few percent and then array 700-PB modules are charged one or a few percent, then array 700-PC modules are charged one or a few percent, and the process can repeat until all modules are fully charged). As mentioned above, if cycling of routing circuity 1200 occurs rapidly during DC charging, arrays 700 can be effectively charged with DC pulse charging. In single-phase AC charging, switching can also occur rapidly such that each array 700-PA through 700-PC is charged one or more times during the positive half of the cycle and charged again one or more times during the negative half of the cycle.Section 10: Example Embodiments of Charging Energy Systems Through a Motor

[0303] Energy system 100 can also be configured to charge primary subsystem 1000 through a motor 1100, such that adaptive routing circuitry 1200 is not needed. FIG. 14 is a block diagram depicting an example embodiment of energy system 100 similar to that of FIG. 11 A, but with a dual DC and single-phase AC charge connector 2002 that can be integrated with three-phase charge connector 1102 in a single user-accessible location or can be separate therefrom and in a different location (e.g., on an EV). Dual connector 2002 is connected to a first line 2004-1 that is in turn connected to a phase port of motor 1100, which in this embodiment is PC and TCP switch 1108-PC. Connector 2002 is connected to a second line 2004-2 that is connected to a system output port SIO4 of primary subsystem 1000. The system output port SIO4 can be a module output port 2 of an interconnection module 108IC-2 connected to array 700-PC, or an output port 2 of a module 108-N of array 700-PC if no IC module is present. Connector 2002 can be connected to positive and negative DC leads for DC charging, or AC(L) and AC(N) leads for single-phase AC charging, which in this example are connected to lines 2004-1 and 2004-2, respectively. Other connections can also be implemented.

[0304] DC and single-phase AC charging can be performed such that one, two, or all three of primary subsystem 1000’s arrays 700 are charged at the same time. DC and AC charging can be performed in a manner that seeks to balance temperature differentials between modules 108 of the arrays 700 as described in Section 2, and to reach a balancedSOC across all modules 108 (also described in Section 2). AC charging is performed to maintain a power factor at or near unity. In all cases, if measurable current passes through the motor 1100’s coils or windings, and fluxes are generated, then the sensors (e.g., monitory circuitry 208 and circuits 1110) of energy system 100 will detect this current, and control system 102 will control the switching of each module 108 such that the magnitude and phase of all fluxes through all windings cancel or neutralize each other, or substantially cancel or neutralize each other such that any variation in fluxes is less than a threshold and insufficient to cause the motor 1100 to turn.

[0305] Note, in the embodiments described with reference to FIG. 14 below, control system 102 can bypass primary converter 420 (and auxiliary converter 430 if present) during DC and single-phase AC charging of primary subsystem 1000 via dual connector 2002. This effectively isolates DC bus 415 from AC bus 410 and DC buses 1131 and 1132, allowing auxiliary subsystem 2000 to operate continuously on DC bus 415. Since the DC- or AC(N) charge signals are presented to a (virtual) zero potential of primary subsystem 1000 at system output port SIO4, the DC+ or AC(L) signals are generally not suitable for charging auxiliary subsystem 2000. However, for three-phase charging of energy system 100 via three-phase charge connector 1102, control system 102 can control primary converter 420 (and auxiliary converter 430 if present) to charge primary 1000 and auxiliary 2000 subsystems concurrently, analogous to that described above in FIGs. 11 A and 1 IB.Section 11: DC Charging Each Array Sequentially Through a Motor

[0306] To charge array 700-PA, TCP switch 1108-PA is placed in position 1 to connect array 700-PA to motor 1100. TCP switches 1108-PB and 1108-PC are placed or kept in position 2. Upon application of the DC charge voltage, current enters the DC+ port of connector 2002, passes through line 2004-1 to motor 1100, where it passes through the PC and PA windings of motor 1100. The current exits motor 1100, passes through TCP switch 1108-PA and monitor circuitry 1110-PA positioned on node NPA of AC bus 410. Current then passes through array 700-PA, where each module 108-1 through 108-N can be individually charged by switching the respective converters 202 according to the techniques described in Sections 3 and 5. Charge current for interconnection modules 108IC-1 and 108IC-2 can pass through S7 of switch portion 604-PA, charge energy sources 206 of modules 108IC-1 and 108IC-2 (in parallel as shown in FIG. 10E), and exits module 108IC-2 through module IO port 2, which can be placed along the rail (the node of IO port 6) as shown in FIG. 10E orbetween S7 and S8 of an additional switch portion 604. Current then exits energy system 100 through the DC- port of connector 2002.

[0307] To charge array 700-PB, TCP switch 1108-PB is placed in position 1 to connect array 700-PB to motor 1100. TCP switches 1108-PA and 1108-PC are placed or kept in position 2. Current passes from the DC+ port of connector 2002, through line 2004-1 to motor 1100, then through the PC and PB windings of the motor 1100. The current then passes through TCP switch 1108-PB and monitor circuitry 1110-PB positioned on node NPB of AC bus 410. Current then passes through array 700-PB, where each module 108-1 through 108-N can be individually charged by switching the respective converters 202 according to the techniques described in Sections 3 and 5. Charge current for modules 108IC-1 and 108IC-2 can pass through S7 of switch portion 604-PB, charge sources 206 of modules 108IC-1 and 108IC-2 (in parallel as shown in FIG. 10E), and exit module 108IC-2 through module IO port 2, exiting energy system 100 through the DC- port of connector 2002.

[0308] To charge array 700-PC, TCP switch 1108-PC is placed in position 1 to connect array 700-PC to line 2004-1. Switches 1108-PA and 1108-PB are placed or kept in position 2. Current passes from the DC+ port of connector 2002, through line 2004-1, bypasses motor 1100, passes through switch 1108-PC and monitor circuitry 1110-PC positioned on node Npc of AC bus 410. Current then passes through array 700-PC, where each module 108-1 through 108-N can be individually charged by switching the respective converters 202 according to the techniques described in Sections 3 and 5. Charge current for modules 108IC-1 and 108IC- 2 can pass through S7 of switch portion 604-PC, charge sources 206 of modules 108IC-1 and 108IC-2 (in parallel as shown in FIG. 10E), and exit module 108IC-2 through module IO port 2, exiting system 100 through the DC- port of connector 2002. To stop charging sources 206 of modules 108IC, S8 of the relevant switch portion 604 can be activated to direct the current directly to port 2 of module 108IC-2.Section 12: DC Charging Two or More Arrays Concurrently Through a Motor

[0309] To charge two or more of primary subsystem 1000’s arrays 700 concurrently with the DC charge signal provided at connector 2002, then the TCP switches 1108 connected to the arrays 700 to be charged are placed or kept in position 1 and the TCP switches 1108 connected to any array 700 not being charged is placed or kept in position 2. To stop charging sources 206 of modules 108IC, then S8 of each switch portion 604 of an array 700 being charged can be activated, or switch portions 604 of the arrays 700 being charged can be modulated at 50-50 duty cycles. Current through the arrays 700 being charged is regulated bythe modules 108 to maintain canceling fluxes through motor 1100, and also to charge energy sources 206 of the modules 108 while balancing one or more operating characteristics of the modules 108 (e.g., temperature and SOC) according to the techniques described in Section 2.Section 13: Single-phase AC Charging All Arrays Concurrently Through a Motor

[0310] To charge all of primary subsystem 1000’s arrays 700 concurrently with a singlephase AC signal provided at connector 2002, TCP switches 1108 are placed or kept in position 1. Current from line 2004-1 is supplied to array 700-PA through the PC and PA windings of motor 1100, supplied to array 700-PB through the PC and PB windings of motor 1100, and supplied to array 700-PC directly from line 2004-1 (bypassing motor 1100). Current then passes through each of arrays 700-PA, 700-PB, and 700-PC and modules 108IC-1 and 108-IC2, exiting through IO port 2 of module 108IC-2. Current through arrays 700 is regulated by the modules 108 to maintain canceling fluxes through motor 1100, such as by causing the current through windings PA and PB to equal that through winding PC, with all currents in the same phase, thus neutralizing the fluxes. Energy sources 206 of modules 108 can be charged while balancing one or more operating characteristics of the modules 108 (e.g., temperature and SOC) according to the techniques described in Section 2.Section 14: Single-phase AC Charging Each Array (or a Subset of Arrays) Concurrently Through a Motor

[0311] To charge one or a subset of primary subsystem 1000’s arrays 700 concurrently with a single-phase AC signal provided at connector 2002, the TCP switches 1108 corresponding to the arrays 700 being charged are placed or kept in position 1 while the other TCP switches 1108 are placed or kept in position 2. Current from line 2004-1 is supplied to the array(s) 700 being charged, either through the windings of motor 1100 or circumventing motor 1100 if array 700-PC is charged. Current then passes through the array(s) 700 being charged and modules 108IC-1 and 108-IC2, exiting through IO port 2 of module 108IC-2. Current through the array(s) 700 being charged is regulated by the modules 108 to maintain canceling fluxes through motor 1100, which is relatively straightforward if only two windings are used (e.g., PA and PC, PB and PC, or PA and PB). Energy sources 206 of modules 108 can be charged while balancing one or more operating characteristics of the modules 108 (e.g., temperature and SOC) according to the techniques described in Section 2.

[0312] In the aforementioned charging embodiments of energy system 100, both when bypassing primary load 101 (e.g., a motor) and when charging through a motor 1100,switches 1108 are switched to positions that permit current flow through the one or more arrays 700 of primary subsystem 1000 being charged and prevent current flow through any array 700 not being charged. Alternatively, all switches 1108 can be placed in a position that permits current flow through the array 700 not being charged which can be regulated using the modules 108 of that array 700 and any interconnection module(s) 108IC coupled to that array 700. Some current flow through an array 700 not being charged may be desired, for example, to assist in neutralizing fluxes within a motor.Section 15: Charging Delta and Series Topologies

[0313] The charging subject matter described herein can be used with topologies having delta and series arrangements of modules 108, similar to those described with respect to FIGs. 7D and 7E. FIG. 15A is a block diagram depicting an example embodiment of energy system 100 having a primary subsystem 1000 with a delta and series arrangement similar to that of FIG. 7E, but with the addition of interconnection modules 108IC-1 and 108IC-2 supplying LV auxiliary loads 301 and 302, as well as DC bus 1131 connecting to auxiliary converter 430. This embodiment is configured for three-phase charging through connector 1102, or DC or single-phase AC charging through connector 1202. Three-phase charging of primary 1000 and auxiliary 2000 subsystems can occur directly from three-phase charge connector 1102. For DC and single-phase AC charging of primary subsystem 1000, because arrays 700-PA, 700-PB, and 700-PC are interconnected by lines 1211, the DC+ and AC(L) current from line 1211-1 can be input directly to module 108-1 of array 700-PC and module 108-(M) of array 700-PB, and circulated from there to the rest of modules 108 of primary subsystem 1000. Current from DC and single-phase AC charging can exit via module 108IC- 2 and line 1211-2. Similar to the embodiments described with reference to FIG. 14 described above, during DC and single-phase AC charging of primary subsystem 1000, control system 102 can bypass primary converter 420 (and auxiliary converter 430 if present) such that DC bus 415 is isolated and auxiliary subsystem 2000 can operate continuously.

[0314] FIG. 15B is a block diagram depicting another example embodiment of energy system 100 having a similar arrangement to that of FIG. 15 A, but with routing circuitry 1200 coupled between dual charge connector 1202 and three-phase charging lines 1111. In this embodiment, routing circuity 1200 can be configured according to FIG. 13C. Accordingly, this delta and series topology can be charged using either a three-phase, single-phase, or DC charge source as described throughout Sections 8-15.Section 16: Additional Example Embodiments of Charging and Discharging Energy Systems

[0315] FIG. 16A is a block diagram depicting an example embodiment of energy system 100 having multiple primary subsystems 1000-1, 1000-2, and 1000-3 for powering three respective primary loads 101-1, 102-1, and 101-3 (e.g., motors of an EV) via respective AC buses 410-1, 410-2, and 410-3. Energy system 100 also includes two auxiliary subsystems 2000-1 and 2000-2 for powering two respective HV auxiliary loads 303-1 and 303-2 (e.g., an HVAC and an onboard electrical system of the EV) via respective DC buses 415-1 and 415- 2. Primary subsystems 1000 can be configured according to FIG. 16C which depicts an example embodiment of a module-based energy system. Auxiliary subsystems 2000 can be configured according to FIGs. 1 IE-11G as described in Section 8. Each of the subsystems 1000 and 2000 can be configured as a separate battery pack housed within a common enclosure and having a dedicated thermal management system (see FIGs. 22A-24J as described in Section 20 for example). Arrays 700 of each of the primary subsystems 1000 can have a different number of modules 108 and / or have modules 108 with different characteristics to facilitate different voltage demands of the loads 101. For example, modules 108 can use different battery types with different nominal voltages or use multiple energy sources 206. In certain other embodiments, the number and characteristics of modules 108 may be consistent between primary subsystems 1000.

[0316] As shown in FIG. 16C, an interconnection module 108IC is present for each primary subsystem 1000. Each interconnection module 108IC includes three switch portions 604 connected to three different arrays 700 of their respective primary subsystem 1000. In this embodiment, each primary subsystem 1000 can be under the control of a separate control system 102 that interfaces with that subsystem 1000’s associated load 101, primary converter 420, and auxiliary converter 430 (if present). Modules 108IC are interconnected to provide power for LV auxiliary loads 301 and 302 over DC buses 1131 and 1132. In an alternative embodiment, each module 108IC can couple to at least two different primary subsystems 1000. In this alternative embodiment, the components of system 100 can be under the control of a common control system 102 that can interface with the controllers for all three loads 101, collects the status information of each primary subsystem 1000, controls each primary 420 and auxiliary 430 converter, and is configured to perform inter-array balancing between primary subsystems 1000 via interconnection modules 108IC.

[0317] In more detail, primary subsystem 1000-1 is coupled to auxiliary subsystem 1000- 1 by way of primary converter 420-1 which allows primary subsystem 1000-1 to supply current and power from three-phase outputs PA, PB, and PC to HV auxiliary load 303-1 overDC bus 415-1. DC bus 415-1 is also connected to DC bus 1131 by auxiliary converter 430 which allows DC current and power to transfer between auxiliary subsystem 2000-1 and interconnection modules 108IC of all three primary subsystems 1000. Similarly, primary subsystem 1000-3 is coupled to auxiliary subsystem 2000-2 by way of primary converter 420-2 which allows primary subsystem 1000-3 to supply current and power from three-phase outputs PG, PH, and PI to HV auxiliary load 303-2 over DC bus 415-2. Note, auxiliary subsystems 2000-1 and 2000-2 may be configured to output a different DC voltage onto their respective DC buses 415-1 and 415-2. For example, HV auxiliary load 303-1 may have higher voltage, current, and / or power demands than HV auxiliary load 303-2 and therefore is configured to receive supplemental power from interconnection modules 108IC. In this case, primary subsystem 1000-2 is not coupled to an auxiliary subsystem 2000 by a primary converter 420 and therefore only supplies three-phase power to load 102-2. In this case, load 101-2 may have higher voltage, current, and / or power demands than loads 101-1 and 101-3, and therefore has a dedicated primary subsystem 1000-2. For example, loads 101-1 and 101-3 may be motors each associated with a front wheel of an EV and load 101-2 may be a motor associated with two back wheels of the EV.

[0318] In FIG. 16A, lines 1111 connect with TCP switches 1108 within switch assemblies 1250-1, 1250-2, and 1250-3 which selectively connect respective loads 101-1, 101-2, and 101-3 to corresponding AC buses 410-1, 410-2, and 420-3. One, two, or all three switch assemblies 1250 can also be configured with on / off switches similar to FIG. 13A for selectively connecting loads 101 to AC buses 410. In these cases, one or more of the switch assemblies 1250 may also include an additional sets of on / off switches (e.g., switches 1331 in FIG. 13D) for selectively connecting lines 1111 to one or more of the AC buses 410. Connectors 1102 / 1202 can be shared as shown in FIG. 16A and routing circuitry 1200 can be configured in accordance with FIG. 12G. Alternatively, connectors 1102 / 1202 can be separate and discrete connectors 1102 and 1202 with at least five charge conductors and routing circuitry 1200 can be configured in accordance with FIGs. 12B, 12H, or 13C. Switch assemblies 1250 can selectively connect each AC bus 410 to lines 1111 to allow each primary subsystem 1000 and an associated auxiliary subsystem 2000 to be charged sequentially through DC, single-phase AC, or three-phase AC charge signals routed through routing circuitry 1200 to their respective AC bus 410. In some cases, two or all three of the primary subsystems 1000 and their associated auxiliary subsystems 2000 can be charged in parallel.

[0319] FIG. 16B shows another example embodiment of energy system 100 including three primary subsystems 1000-1, 1000-2, and 1000-3. This embodiment is configured similarly to the embodiment of FIG. 16A except the primary subsystems 1000 output three- phase AC power in parallel onto a common AC bus 410 for delivery to a shared primary load 101. For example, primary load 101 may be a HV motor of an EV, e.g., an electric bus or other large EV, that has relatively high power demands. A primary converter 420 is coupled between AC bus 410 and a DC bus 415 to supply supplemental power to a HV auxiliary load 303 (e.g., an HVAC system of an electric bus or other large EV) and / or charging of an auxiliary subsystem 2000. Switch assembly 1250 is configured to connect or disconnect primary load 101 to AC bus 410 and includes an on / off switch 1108 for each phase PA, PB, and PC of AC bus 410. Routing circuitry 1200 is coupled to AC bus 410 to route DC, singlephase, or three-phase charge signals from charge connector 1102 / 1202 which can be utilized by the primary subsystems 1000 for parallel charging and / or be converted to DC charge signals by primary converter 420 for charging auxiliary subsystem 2000. Similar to the embodiment of FIG. 16 A, connectors 1102 / 1202 can be shared as shown in FIG. 16B and routing circuitry 1200 can be configured in accordance with FIG. 12G. Alternatively, connectors 1102 / 1202 can be separate and discrete connectors 1102 and 1202 with at least five charge conductors and routing circuitry 1200 can be configured in accordance with FIGs. 12B, 12H, or 13C.

[0320] Energy system 100 has a highly scalable and adaptable configuration that permits numerous different implementations to power applications having a wide breadth of voltage requirements and quantity of loads. The voltage requirements can vary from low-voltage applications (e.g., electric scooters, etc.) on the order of hundreds of watts, to high-voltage industrial applications (e.g., power grids, fusion research, etc.) on the order of megawatts, and higher. The number of loads can vary and those loads can be supplied power by multiple primary 1000 and auxiliary 2000 subsystems that are interconnected by one or more primary converters 420, one or more interconnection modules 108IC, and one or more auxiliary converters 430 under the control of a common control system 102 (or multiple separate control systems in some cases as described above). The scalability and adaptability of system 100 applies both to stationary and mobile applications. To ease illustration, many of the embodiments described herein are with respect to mobile applications, particularly various embodiments of automotive EVs, although not limited to such.

[0321] The example embodiments can be used with automotive EVs having a single motor and one or more associated primary subsystems 1000 (e.g., module-based batterypacks) and one or more auxiliary subsystems 2000 (e.g., conventional battery packs). Example embodiments of system 100 can also be used with automotive EVs having two or more motors associated with a single primary subsystem 1000, or two or more motors each having one or more primary subsystems 1000 associated therewith. Such embodiments of system 100 can include one or more auxiliary subsystems 2000 coupled to the primary subsystems 1000 by one or more primary converters 420 to provide robust power management for primary loads 101 and HV auxiliary loads 303. The motors can be motors mounted within the vehicle body that transfer power to the wheels by way of a powertrain or drivetrain. The motors can alternatively be in-wheel motors that power wheel motion directly without a powertrain (or drivetrain). The EV may have an in-wheel motor for every wheel on the vehicle (e.g., 2, 3, 4, 5, 6, or more), or may have in-wheel motors for only some of the wheels on the vehicle. If multiple motors are present, a combination of approaches can be used, e.g., in-wheel motors for front wheels of the EV and an in-body motor and powertrain for rear wheels, or vice versa.

[0322] The present subject matter provides the capability for different subsystems 1000 and 2000 to provide power for primary and auxiliary loads having different voltage requirements. For example, a single four-wheel EV can have a first motor for powering the front wheels and a second motor for powering the rear wheels. The first motor may operate at a different voltage than the rear motor. Alternatively, the EV may have one motor for each front wheel and one motor for both rear wheels, where the motors for the front wheels have different voltage requirements than the motor for the rear wheels. Or the EV may have one motor for the front wheels and two motors for the rear wheels, with the rear wheel motors having different voltage requirements than the front wheel motor. Still further, each wheel can have its own motor, with front wheel motors having a voltage requirement that is different from the voltage requirement of the rear wheel motors. Such variable combinations also apply to multi-motor EVs having two, three, five, six, or more wheels. As another example, a (HV) auxiliary load 303 may have a higher voltage requirement than another (LV) auxiliary load 301 and can be placed on a DC bus 415 while LV auxiliary load 301 can be managed by interconnection modules 108IC, e.g., over DC bus 1131.

[0323] A motor having a relatively low-voltage requirement, e.g., 300-400 V nominal line-to-line peak voltage, may have a primary subsystem 1000 with relatively fewer modules than a higher voltage application. Alternatively, or in addition, each module may have a lower nominal voltage than those of a higher voltage application. To a similar effect, a HV auxiliary load 303 having a lower voltage requirement than a higher voltage application mayhave an auxiliary subsystem 2000 with a fewer number of energy sources and / or energy sources with lower nominal voltages. A motor having a relatively moderate-voltage requirement that is higher than the low-voltage requirement, e.g., a 400-700 V nominal line- to-line peak voltage, may have a primary subsystem 1000 with relatively more modules per array than the low-voltage primary subsystem 1000, and / or those modules may have the same or a higher nominal voltage than those of the low-voltage application. By further example, a motor having a relatively high-voltage requirement, higher than the low and / or moderatevoltage requirements, e.g., a 700V-800V nominal line-to-line peak voltage, may have a primary subsystem 1000 with relatively more modules per array than the low-voltage and moderate-voltage primary subsystems 1000, and / or, the nominal voltages of those modules may be relatively higher than those of the low-voltage or moderate-voltage primary subsystems 1000. Of course, all primary subsystems 1000 can be configured with the same number of modules and only the nominal voltage of the modules may vary, or all primary subsystems 1000 can be configured with modules having the same nominal voltage but with different numbers of modules per array. Similarly, all auxiliary subsystems 2000 can be configured with the same number of energy sources and only the nominal voltage of the energy sources vary, or all auxiliary subsystems 2000 can be configured with energy sources having the same nominal voltage but with different numbers of energy sources.

[0324] The present subject matter also provides the capability to use energy sources of the same class but of different types (e.g., different electrochemistry, different physical structure, etc.) for different modules, different subsystems 1000 and 2000, and different systems 100 as a whole. For example, one or more first primary subsystems 1000 in a multimotor EV may have modules 108 with batteries of a first type and one or more second primary subsystems 1000 in a multi-motor EV may have modules 108 with batteries of a second type. In a similar vein, one or more auxiliary subsystems 2000 may include batteries of the first type, the second type, or of a third type different from the first and second types. If interconnection modules 108IC are present, then those modules 108IC may have batteries of a fourth type different from the first, second, and third types.

[0325] If one or more primary subsystems 1000 have modules 108 with multiple energy sources per module (e.g., modules 108B, 108D, and 108E in FIGs. 3B, 18 A, and 18B respectively), then still further combinations can be practiced, such as combinations where: (a) the one or more first primary subsystems have multiple energy sources per module, and the one or more second primary subsystems have only one energy source per module, (b) the one or more first primary subsystems have multiple energy sources per module including aprimary energy source 206A of a first type and a secondary energy source 206B of a second type, and the one or more second primary subsystems have multiple energy sources per module including a primary energy source 206A of the same first type and a secondary energy source 206B of a third type different from the first and second types, (c) the one or more first primary subsystems have multiple energy sources per module including a primary energy source 206A of a first type and a secondary energy source 206B of a second type, and the one or more second primary subsystems have multiple energy sources per module including a primary energy source 206A of a third type, different from the first and second types, and a secondary energy source 206B of the same second type, or (d) the one or more first primary subsystems have multiple energy sources per module and the one or more second primary subsystems have multiple energy sources per module, and the types of energy sources in the one or more first primary subsystems are different than the types of energy sources in the one or more second primary subsystems.

[0326] Type differences between energy sources can manifest in terms of the operating characteristics of those energy sources. For example, battery energy sources of different types may have different nominal voltages, different C rates, different energy densities, different capacities, each of which may vary over temperature, state of charge, or usage (e.g., the number of cycles). Examples of battery types include solid-state batteries, liquid electrolytebased batteries, liquid phase batteries as well as flow batteries such as lithium (Li) metal batteries, Li-ion batteries, Li-air batteries, sodium-ion batteries, potassium-ion batteries, magnesium-ion batteries, alkaline batteries, nickel-metal hydride batteries, nickel sulfate batteries, lead acid batteries, zinc-air batteries, and others. Some examples of Li-ion battery types include Li cobalt oxide (LCO), Li manganese oxide (LMO), Li nickel manganese cobalt oxide (NMC), Li iron phosphate (LFP), Li nickel cobalt aluminum oxide (NCA), and Li titanate (LTO).

[0327] Thus, battery types can be mixed to achieve superior performance over different operating characteristics. These variations in voltage capability (e.g., low, moderate, high) and energy source type can be applied to all the embodiments described herein. These variations are particularly applicable to embodiments having two or more separate primary subsystems 1000 to power multiple motors, interconnected with one or more auxiliary subsystems 2000, such as those described with respect to FIGs. 16A-16C. When charging primary subsystems 1000 having different voltage capabilities, each primary subsystem 1000 can be charged independently by a dedicated charge port and charge cable (from a dedicated charge source or a shared charge source). Alternatively, the primary subsystems 1000 can becharged concurrently from the same charge cable and connector, such as the parallel configurations, taking the voltage level of the charge signals, number of modules 108, and the nominal voltage rating of the modules 108 in each primary subsystem 1000s’ arrays 700 into consideration. An auxiliary subsystem 2000 can be charged concurrently with one or more primary subsystems 1000 by connecting one or more primary converters 420 to the respective phase outputs of the one or more primary subsystems 1000.

[0328] When charging any of the embodiments of energy system 100 described herein, if desired to preserve enough margin to perform balancing during the charging process, it is preferable that the available charge source voltage (e.g., peak line-to-line voltage for AC charging) be less than the sum total of the present voltages of the sources 206 being charged at any one time.Section 17: Example Embodiments of Energy Systems for Applications with Intermittent Charging

[0329] Example embodiments pertaining to energy systems 100 used in applications with intermittently available charge sources are described with reference to FIGs. 17-20D. These embodiments can be implemented with all aspects of the module-based energy systems described with respect to FIGs. 1 A-10F unless stated otherwise or logically implausible. As such, the many variations already described will not be repeated with respect to the following embodiments. These example embodiments are particularly suited for mobile applications, such as electric vehicles that operate on a rail (rail-based EVs) like trains, trams, trolleys, and other rolling stock, where the charge source is intermittently available. For example, the charge source can be a catenary that supplies charge signals for the EV via an overhead power system. The embodiments can be used with other vehicles as well, such as cars, buses, trucks, maritime vehicles (e.g., electric ferries), planes, etc., and even in some stationary applications. Examples of these and further configurations are described in IntT. Appl. No. PCT / US2021 / 032295, filed May 13, 2021, and titled Systems, Devices, and Methods for Rail-Based and Other Electric Vehicles with Modular Cascaded Energy Systems, which is incorporated by reference herein in its entirety for all purposes.

[0330] FIG. 17 is a block diagram depicting an example embodiment of an energy system 100 configured for intermittent direct DC charging. System 100 includes three primary subsystems 1000-1, 1000-2, and 1000-3, and an auxiliary subsystem 2000. Primary subsystems 1000 can be configured according to FIGs. 18A-20D and auxiliary subsystem 2000 can be configured according to FIGs. 1 IE-11G, or otherwise appropriate. Each of thesubsystems 1000 and 2000 can be configured as a separate battery pack housed within a respective enclosure having a dedicated thermal management system (see FIGs. 22A-24J described in Section 20 for example). The phase outputs PA, PB, and PC of primary subsystems 1000 are connected to respective primary loads 101-1, 101-2, and 101-3 via respective AC buses 410-1, 410-2, and 410-3 to provide three-phase AC power for the loads 101. For example, each load 101 may correspond to a motor of an EV, such as a rail-based EV. Primary subsystems 1000-1, 1000-2, and 1000-3 also provide power to a common DC bus 415 through respective primary converters 420-1, 420-2, and 420-3. In other embodiments, one or two of the primary subsystems 1000 may be coupled to DC bus 415 through respective primary converters 420 as many topologies are feasible. The auxiliary subsystem 2000 is connected to the DC bus 415 to output a DC voltage onto the DC bus 415 and supply power for a HV auxiliary load 303.

[0331] Each primary subsystem 1000 is connected to sets of shared DC lines 1130 and DC buses 1131 and 1132, for sharing DC power at various voltage levels. DC lines 1130 of the energy system 100 can carry high-voltage positive and negative DC signals, DC_CS+ and DC CS-, respectively, from charge source 150, for supplying charge voltage to all of the modules 108 of each primary subsystem 1000, as well as to auxiliary subsystem 2000. The shared DC lines 1130 can also exchange lower DC voltages through modules 108 of the primary subsystems 1000 for supplying power to LV auxiliary loads 301 and 302. DC bus 1131 can carry positive and negative DC signals, DC1+ and DC1-, respectively, for supplying a lower DC voltage to LV auxiliary load 301. For example, DC bus 1131 can be similar to the lines interconnecting ports 3 and 4 of IC modules 108IC (and 108C) as described with respect to FIGs. 3C, 10D, and 10E, and can carry the output DC voltage of the energy sources 206 of the modules 108. DC bus 1132 can carry positive and negative DC signals, DC2+ and DC2-, respectively, for supplying a lower DC voltage to LV auxiliary load 302. For example, DC bus 1132 can be similar to the lines interconnecting ports 5 and 6 of IC modules 108IC (and 108C) as described with respect to FIGs. 3C, 10D, and 10E, and can carry a regulated stepped-down DC voltage from sources 206 of the modules 108.

[0332] Auxiliary converter 430-2 can convert the high DC voltage available on DC lines 1130 into DC power for HV auxiliary load 303 and auxiliary subsystem 2000. In this embodiment, auxiliary converter 430-2 is configured to convert DC power from DC lines 1130 to DC power for DC bus 415 at the appropriate voltage output by auxiliary subsystem 2000. When connected to charge source 150, auxiliary converter 430-2 can use the DCvoltage provided by charge source 150 over DC lines 1130 to power HV auxiliary load 303 and / or charge auxiliary subsystem 2000. As described with respect to FIG. 18B, when not connected to charge source 150, the primary subsystems 1000 can provide the power to auxiliary converter 430-2 over DC lines 1130 by outputting DC voltages from ports 7 and 8 of one or more modules 108E to DC lines 1130 using bidirectional DC-DC converters 1610. The DC output voltages from multiple modules 108E can be summed on the DC lines 1130 to provide a desired amount of power to auxiliary converter 430-2. As shown in FIG. 20B, arrays 700-PA, 700-PB, and 700-PC of each of the primary subsystems 1000 are interconnected by three interconnection modules 108IC-1, 108IC-2, and 108IC-3 which output DC voltages DC1+ / - and DC2+ / - onto DC buses 1131 and 1132, respectively. Interconnection modules 108IC provide power to LV auxiliary loads 301 and 302 connected to DC buses 1131 and 1132, as well as to DC bus 415 which is connected to DC bus 1131 through auxiliary converter 430-1.

[0333] FIG. 18A is a block diagram depicting an example embodiment of module 108D configured for use within primary subsystems 1000 of the energy system 100 shown in FIG. 17. In all the embodiments described herein, module 108D can include any number of energy sources 206, such as one or more batteries, one or more high energy density (HED) capacitors, and / or one or more fuel cells. If multiple batteries are included those batteries can have the same or different electrochemistries as described herein. Similarly, different types of high-energy density (HED) capacitors and fuel cells can be used. Each battery can be a single cell or multiple cells connected in series, parallel, or a combination thereof to arrive at the desired voltage and current characteristics. As shown in FIG. 18 A, module 108D includes a primary source 206 A and a secondary source 206B. The energy sources 206 A and 206B can be batteries of different types (e.g., such as an LTO battery and an LFP battery) or one can be a battery and the other can be an HED capacitor, or any other combination of energy sources 206 as described herein.

[0334] Module 108D includes converter 202B or 202C coupled with energy sources 206 A and 206B in a manner similar to that described with respect to module 108B of FIG. 3B. Energy source 206A is coupled with energy buffer 204, which in turn is coupled with a unidirectional isolated DC-DC converter 1600. Module 108D includes IO ports 7 and 8 that connect with the charge source signals DC CS+ and DC CS- respectively, via DC lines 1130 over power connection 111. These signals are input to DC-AC converter 1602 of converter1600 where they are converted to high-frequency AC form and then input to transformer and rectifier section 1604.

[0335] Transformer and rectifier section 1604 can include a high-frequency transformer and single-phase diode rectifier. The DC voltage over power connection 111 may be a voltage that is lower than the total voltage supplied by the charge source 150 as primary subsystem 1000 may include many such modules 108 receiving charge simultaneously. Transformer and rectifier section 1604 can modify the voltage of the AC signal from converter 1602, if necessary, and convert the AC signal back into DC form to charge sources 206A and 206B. Section 1604 also provides high-voltage isolation to the other components 202, 204, 206, and 114 of module 108D.

[0336] Unidirectionality is provided by the diode rectifier which permits current to be received from charge source 150 and passed to buffer 204 but does not permit outputting current in the opposite manner. For example, upon braking, if an EV has an energy recovery system then the current from braking can be transferred back to each module 108D through power connection 110 and routed to either of sources 206 A and 206B by way of converter 202B,C. The presence of unidirectional DC-DC isolated converter 1600 (diode rectifier) will prevent that recovered energy from passing through module 108D back to the charge source via DC lines 1130.

[0337] LCD 114 can monitor the status of converter 1600, particularly converter 1602 and section 1604, over data connections 118-5 and 118-6, respectively. As with the other components of module 108D, monitor circuitry for converter 1602 and section 1604 can be included to measure currents, voltages, temperatures, faults, and the like. These connections 118-5 and 118-6 can also supply control signals to control switching of converter 1602 and to control any active elements within section 1604. Isolation of LCD 114 can be maintained by isolation circuitry present on lines 118-5 and 118-6 (e.g., isolated gate drivers and isolated sensors).

[0338] FIG. 18B is a block diagram depicting an example embodiment of a module 108E. Module 108E is configured similarly to that of module 108D but has a bidirectional DC-DC isolated converter 1610 instead of a unidirectional DC-DC converter 1600, and can perform bidirectional energy exchange between sources 206 (or power connection 110) and ports 7 and 8 connected to DC lines 1130. Bidirectional converter 1610 can route current from power connection 111 to charge sources 206A and 206B (through converter 202B,C), route current from power connection 111 to power the load (by outputting from converter 202B,C to power connection 110), route current from sources 206A and / or 206B (with converter 202B,C) topower connection 111 (e.g., for powering one or more high-voltage auxiliary loads), and route current from sources 206A and / or 206B (via converter 202B,C) to power connection 111 for charging other modules 108E of primary subsystem 1000 by way of DC lines 1130.

[0339] Bidirectional converter 1610 is connected between ports 7 and 8 and energy buffer 204. Converter 1610 includes DC-AC converter 1602, connected to transformer 1606, which in turn is connected to AC-DC converter 1608. DC-AC converter 1602 can convert the DC voltage at ports 7 and 8 into a high-frequency AC voltage, which transformer 1606 can modify to a lower voltage if needed, and output that modified AC voltage to AC-DC converter 1608, which can convert the AC signal back into DC form for provision to sources 206A, 206B, or module ports 1 and 2. Transformer 1606 can also isolate module components 202, 204, 206, 1608, and 114 from the DC voltage at ports 7 and 8. As with the other components of module 108E, monitor circuitry for DC-AC converter 1602, transformer 1606, and AC-DC converter 1608 can be included to measure currents, voltages, temperatures, faults, and the like. LCD 114 can monitor the status of converter 1610, particularly DC-AC converter 1602, transformer 1606 (e.g., monitor circuitry or an active component associated therewith), and AC-DC converter 1608, over data connections 118-5, 118-7, and 118-8, respectively. These connections 118-5 and 118-6 can also supply control signals to control switching of converter 1602 and to control any controllable elements associated with transformer 1606. Isolation of LCD 114 can be maintained by isolation circuitry present on lines 118-5 and 118-6 (e.g., isolated gate drivers and isolated sensors).

[0340] Furthermore, for electrochemical battery sources 206, the length of the charge pulses applied to sources 206 by AC-DC converter 1608 can be maintained to have a certain length, e.g., less than 5 milliseconds, to promote the occurrence of the electrochemical storage reaction in the cells without the occurrence of significant side reactions that can lead to degradation. The charge methodology can incorporate active feedback from each energy source to ensure that battery degradation, if detected, is mitigated by lowering voltage or pausing the charge routine for that module, or otherwise. Such pulses can be applied at high C rates (e.g., 5C-15C and greater) to enable fast charging of the sources 206. The duration and frequency of the charge pulses can be controlled by control system 102. Examples of such techniques that can be used with all embodiments herein are described in IntT Publ. No. WO 2020 / 243655, filed May 29, 2020, and titled Advanced Battery Charging on Modular Levels of Energy Storage Systems, which is incorporated by reference herein for all purposes.

[0341] FIG. 19A is a schematic diagram depicting an example embodiment of module 108D. Converter 202B is coupled with secondary source 206B, and in other embodiments can be configured like converter 202C (FIG. 6C). Buffer 204 is configured here as a capacitor. IO ports 7 and 8 are coupled to an LC filter 1302, which is in turn coupled to unidirectional DC-DC converter 1600, specifically DC-AC converter 1602, which is configured as a full-bridge converter with switches S10, SI 1, S12, and S13. LC filter 1302 can be a distributed DC filter that can filter harmonics from and to the DC lines 1130, provide a current slowing function if desired, and / or perform other functions. The full-bridge outputs from nodes N 1 and N2 are connected to a primary winding of transformer 1606 within section 1604. A secondary winding of transformer 1606 is coupled with nodes N3 and N4 of the diode rectifier of section 1604, having diodes D1-D4. The switches of DC-AC converter 1602 can be semiconductor switches configured as MOSFETs, IGBTs, GaN devices, or others as described herein. LCD 114 or another element of control system 102 can provide the switching signals for control of switches S1-S6 and S10-S13. Along with the other functions described herein, converter 202B can be controlled to independently route current from ports 7 and 8 to source 206B for charging, or to IO ports 1 and 2 for powering primary load 101.

[0342] FIG. 19B is a schematic diagram depicting an example embodiment of module 108E. Converter 202B is coupled with secondary source 206B, and in other embodiments can be configured like converter 202C (FIG. 6C). Buffer 204 is configured as a capacitor. IO ports 7 and 8 are coupled to an LC filter 1302, which is in turn coupled to bidirectional DC- DC converter 1610, specifically DC-AC converter 1602, which is configured as a full-bridge converter with switches S10, S 11 , SI 2, and S13. The full-bridge outputs from nodes N1 and N2 are connected to a primary winding of transformer 1606. A secondary winding of transformer 1606 is coupled with nodes N3 and N4 of a second full-bridge circuit configured as AC -DC converter 1608, having switches S14, S15, S16, and S17. The switches of converter 1608 can be semiconductor switches configured as MOSFETs, IGBTs, GaN devices, or others as described herein. LCD 114 or another element of control system 102 can provide the switching signals for control of switches S1-S6 and S10-S17. Along with the other functions described herein, converter 202B can be controlled to independently route current from ports 7 and 8 to source 206B for charging, or to IO ports 1 and 2 for powering a primary load 101.

[0343] FIG. 19C is a schematic diagram depicting another example embodiment of module 108E, where AC -DC converter 1608 is configured as a push-pull converter with afirst terminal of buffer 204 connected to one side of dual secondary windings of transformer 1606 through an inductor L2, and switches S18 and S19 connected between the opposite side of dual secondary windings and a common node (e.g., node 4) coupled with the opposite terminal of buffer 204. The push-pull configuration only requires two switches and thus is more cost-effective than a full-bridge converter, although the switches generally have larger voltages applied across them.

[0344] FIG. 20A is a block diagram depicting an example embodiment of primary subsystem 1000 configured to supply three-phase AC power and no interconnection modules 108IC are present. This embodiment includes three serial arrays 700-PA, 700-PB, and 700- PC with modules 108 arranged in cascaded fashion with ports 1 and 2 daisy-chained between modules as described in Section 4. Primary subsystem 1000 has three arrays 700-PA, 700- PB, and 700-PC for supplying three-phase power to the AC bus 410 by way of system ports SIO1, SIO2, and SIO3. In this embodiment and that of FIG. 20B, each of modules 108 can be configured as module 108D (FIGs. 18A and 19A) or module 108E (FIGs. 18B, 19B, and 19C). A neutral signal is available at SIO6(N) if desired. The DC voltage signals DC CS+ and DC CS- supplied from DC lines 1130 are provided to primary subsystem 1000 by system IO ports SIO5 and SIO4, respectively. Ports 7 and 8 of each of modules 108 are daisy-chained such that the applied charge source voltage is divided across modules 108-1 through 108-N of each array 700. As with other embodiments, primary subsystem 1000 can be configured with N modules 108 in each array 700, where N can be any integer two or greater.

[0345] FIG. 20B is a block diagram depicting another example embodiment of primary subsystem 1000 configured to supply three-phase power and also having interconnection modules 108IC-1, 108IC-2, and 108IC-3. Modules 108IC can have interconnected energy sources 206 and can be configured for interphase balancing between arrays 700 as described in Section 6. Modules 108IC can also be configured to supply DC voltages to DC buses 1131 and 1132 to power one or more LV auxiliary loads 301 and 302, as well as a HV auxiliary load 303 via an auxiliary converter 430 connected between DC bus 415 and DC buses 1131 and / or 1132. The example embodiments of primary subsystem 1000 shown in FIGs. 20A and 20B can be used in any of the energy systems 100 disclosed herein, depending on whether the primary subsystem 1000 is configured to supply power for LV auxiliary loads 301 and 302, whether the primary subsystem 1000 is configured with interphase balancing capability through interconnection modules 108IC, and whether the interconnection modules 108IC are connected to an auxiliary converter 430.

[0346] FIGs. 20C and 20D are schematic diagrams depicting example embodiments of interconnection module 108IC configured for use with the embodiment of primary subsystem 1000 in FIG. 20B. In the embodiments of FIGs. 20C and 20D, interconnection module 108IC has a single switch portion 604 configured to connect IO port 1 to either the positive DC voltage of source 206 (port 3) or the negative DC voltage of source 206 (port 4). A switch portion 602A regulates and steps down the voltage of source 206 for provision as the auxiliary load voltage for DC bus 1132. A filter capacitor C3 can be placed across ports 5 and 6. In FIG. 20C, module 108IC includes bidirectional converter 1610 configured with two fullbridge converters 1602 and 1608 with a transformer therebetween 1606, similar to the embodiment of module 108E in FIG. 19B. In FIG. 20D, the AC -DC converter 1608 of bidirectional converter 1610 is configured as a push-pull converter, similar to the embodiment of module 108E in FIG. 19C.Section 18: Example Embodiments of Power and Control Distribution Assemblies

[0347] As described in Sections 8-17, the interface between energy system 100 and a motor, charge port, control systems, and other subsystems of an EV can be complex. These interfaces can include control devices, drive units, power converters, switches and relays, routing circuitry, sensors, monitor circuits, and associated power and control interconnections (e.g., bus bars and / or wires). Any and all of these interfaces can be housed within a power and control distribution assembly (PCD A) 1250. An EV can include one instance of a PCDA 1250 that handles interfaces with system 100, or the PCDA 1250 can be distributed amongst two or more instances with each instance being associated with interfaces at a particular location of the EV, such as a front axle PCDA and a rear axle PCDA. As described below, each primary 1000 and auxiliary 2000 subsystem of system 100 may also interface with a (local) power distribution unit (PDU) before interfacing with the PCDA 1250.

[0348] FIG. 21 A is a block diagram depicting an example embodiment of PCDA 1250. Here, PCDA 1250 includes a control section 3002, an auxiliary power distribution section 3004, a primary power distribution section 3006, and a power management section 3005.

[0349] Control section 3002 can include various control devices, such as MCD 112 and one or more auxiliary control devices (ACD) 3008-1 through 3008-N. While shown here as an external component, control section 3002 can also include a vehicular ECU 104, either as a discrete device or integrated with MCD 112 as a common control device 132. An ACD 3008 can be a control device responsible for controlling one or more auxiliary EV subsystems of the EV, such as active suspension, electronic steering (e.g., steer-by-wire (SbW)),headlamps and lighting, and / or autonomous driving sensors (e.g., radar devices, millimeter wave radar devices, cameras, far infrared (FIR) cameras, and light detection and ranging (LIDAR) devices). Each of the control devices within PCDA 1250 can communicate with each other, with devices in other sections of PCDA 1250, and with external devices (e.g., vehicular ECU 104) as required. Here, a bidirectional communication interface 105 can communicate control signals and information between the devices of control section 3002 and vehicular ECU 104. Bidirectional communication interfaces 3009-1 through 3009-P can communicate control signals and information between the devices of control section 3002 and any external ACDs 3035-1 through 3035-P, or other systems requiring control input or information from MCD 112 (such as, e.g., routing circuitry 1200 when located external to PCDA 1250). Bidirectional communication interface 115 can communicate information between MCD 112 and the LCDs 114 of each primary subsystem 1000s’ modules 108 (and interconnection modules 108IC if present), as described in Section 2. Similarly, bidirectional communication interface 3031 can communicate control signals from MCD 112 to power management section 3005 to control switching of primary 420 and auxiliary 430 converters of power management section 3005.

[0350] Power management section 3005 includes one or more AC buses 410 (not shown) for transferring AC power to and from one or more primary subsystems 1000-1 through 1000-S over bidirectional power interface 3038. For example, power management section 3005 can include a respective AC bus 410 for each primary subsystem 1000 such that the primary subsystem 1000 outputs AC power of a particular voltage and a particular number of phases onto the AC bus 410 (see FIG. 16A for example). In other embodiments, an AC bus 410 may be coupled to two or more primary subsystems 1000 to sum their output power in parallel (see FIG. 16B for example). Power management section 3005 also includes one or more DC buses 415 (not shown) for transferring DC power to and from one or more auxiliary subsystems 2000-1 through 2000-T over bidirectional power interface 3042. For example, power management section 3005 can include a respective DC bus 415 for each auxiliary subsystem 2000 such that the auxiliary subsystem 2000 outputs DC power at a particular voltage onto the DC bus 415 (see FIG. 16A for example). Power management section 3005 further includes one or more primary converters 420-1 through 420-Q for converting AC power on the one or more AC buses 410 to DC power for the one or more DC buses 415. In some embodiments, power management section 3005 also includes DC buses 1131 and / or 1132 (not shown) for transferring DC power to and from interconnection module(s) 108IC of the one or more primary subsystems 1000 over bidirectional power interface 3039, e.g.,power from ports 3, 4, 5, 6 of the IC module(s). In these cases, power management section 3005 may also include one or more auxiliary converters 430-1 through 430-R for converting DC power between DC buses 415, 1131, and / or 1132.

[0351] Auxiliary power input connection 3010 can route various auxiliary power signals from power management section 3005 (e.g., power from various DC buses 415, 1131, and 1132) to auxiliary power section 3004. Auxiliary power section 3004 can include cabling for routing these auxiliary power signals from power management section 3005 to any auxiliary loads 301, 302, or 303 of the EV (e.g., HVAC, on-board network, internal lighting) over auxiliary power output interfaces 3012 and 3014. Auxiliary power section 3004 can also include one or more power converters 3011 (e.g., for converting DC power on DC buses 415, 1131, and 1132 to DC or AC power at an appropriate voltage). A converter 3011 can be, for example, a DC-DC converter for converting a first DC voltage signal from connection 3010 (e.g., 48V on DC bus 1131 or 500V on DC bus 415) to a lower DC voltage (e.g., 14V) to be output for use by LV auxiliary load 301 over auxiliary output interface 3012. As another example, a converter 3011 can be a DC- AC converter for converting a high-voltage DC signal (e.g., 500V on DC bus 415) from connection 3010 to a high-voltage single-phase or multi -phase AC signal to be output for use by HV auxiliary load 303 over auxiliary output interface 3014. Auxiliary power section 3004 can also include one or more auxiliary drive units 3015-1 through 3015-M for converting auxiliary power from system 100 to drive signals for the associated electromechanical auxiliary subsystems 3033, like active suspension and electronic steering, over drive output interface 3016. Drive units 3015 can be controlled by ACDs 3008. Auxiliary power section 3004 can supply power for control section 3002 over internal power connection 3018. Control signals between auxiliary power section 3004 and control section 3002 can be exchanged over an internal communication interface 3020.

[0352] Primary power distribution section 3006 can include switches 1108 (e.g., relays), routing circuitry 1200, transformers, and / or sensors for measuring and routing power between system 100 and one or more motors 1100, between system 100 and charge port(s) 1102 and / or 1202 (for charging), and between system 100 and any regenerative braking energy recapture devices 2100. In all the embodiments described herein, routing circuitry 1200 can be included within PCDA 1250 as shown here, or can be external to PCDA 1250. When external to PCDA 1250, routing circuitry 1200 can be located within a charge network distributor 3248, such as that depicted in FIG. 21G.

[0353] FIG. 21G is a perspective view depicting an example embodiment of an EV 3000 with a combined three-phase, single-phase, and DC charge port 1102 / 1202. Three-phase cabling 1111 conducts three-phase AC power from port 1102 / 1202 to routing circuitry 1200 within charge network distributor 3248. Dual single-phase / DC cabling 1211 conducts singlephase or DC power from port 1102 / 1202 to routing circuitry 1200 within charge network distributor 3248.

[0354] Referring back to FIG. 21 A, primary power section 3006 can include switches 1108 and monitor circuits 1110 for monitoring the various characteristics (e.g., current, voltage, etc.) of the power signals transferred to and from system 100. Primary power section 3006 can also include safety disconnection devices 3024 (e.g., fuses and / or breakers) for interrupting the current flow to and from system 100, motor(s) 1100, and / or charge port(s) 1102 and / or 1202. In embodiments using one or more AC transformers to provide isolation between system 100 and charge port(s) 1102 and / or 1202, those AC transformers can be located within PCDA 1250 provided adequate space exists.

[0355] Power to and from power distribution section 3006 can be exchanged from the one or more AC buses 410 of power management section 3005 over bidirectional power interface 3030. Power to and from motors 1100 can be exchanged over bidirectional power interface 3032, power to and from charge port(s) 1102 and / or 1202 can be exchanged over bidirectional power interface 3034 (e.g., including connections 1111), and power to and from the energy recapture devices 2100 can be exchanged over bidirectional power interface 3036. Control signals between control section 3002 and primary power distribution section 3006 can be exchanged over an internal communication interface 3040. These control signals can carry control signals being output to routing circuitry 1200 (e.g., CS1-CS4), monitor circuits 1110, and switches 1108, and can return monitored information from monitor circuits 1110 and disconnection state information from safety disconnect devices 3024. Each communication interface of PCDA 1250 can be electrical or optical and can include one or more electrical or optical wires, as well as external and / or internal connectors (e.g., plugs, receptacles) as applicable.

[0356] FIG. 21B is a block diagram depicting an example embodiment of a PCDA 1250 interfacing with an energy system 100 configured for an EV. In this embodiment, power management section 3005 includes an AC bus 410, a DC bus 415, and a primary converter 420 coupling them together. This allows power and current to flow from the primary power section 3006 to the auxiliary power section 3004, e.g., to charge an auxiliary subsystem 2000 and / or when auxiliary loads 301, 303, and 3033 have unexpectedly high power demands.Here, energy system 100 includes one or more primary subsystems 1000-1 through 1000-N and the auxiliary subsystem 2000. Primary subsystems 1000 can be added one by one to energy system 100 and coupled to the AC bus 410 to meet the requisite power needs of the EV. In this embodiment, no IC modules are present to interconnect respective arrays 700-PA, 700-PB, and 700-PC of primary subsystems 1000. For example, each primary subsystem 1000 can be configured according to any of the embodiments in FIGs. 7C-7E and the auxiliary subsystem 2000 can be configured according to any of the embodiments in FIGs. 1 IE-11G, or otherwise appropriate.

[0357] Each primary subsystem 1000 produces three-phase AC power and interfaces with a respective primary PDU 1251 that outputs the power in parallel onto the AC bus 410. The auxiliary subsystem 2000 produces DC power and interfaces with an auxiliary PDU 2251 that outputs the power onto the DC bus 415. A primary 1251 PDU or auxiliary 2251 PDU protects a primary 1000 or auxiliary 2000 subsystem against common utility power problems such as voltage spikes or sags, noise, harmonic distortions on the AC bus 410, etc. For example, each PDU 1251 and 2251 can include safety disconnection devices (e.g., fuses and / or breakers) to protect against voltage spikes. Each primary PDU 1251 can also include inductive interface circuitry (e.g., configured similarly to interface circuity 426 in FIGs. 11H- 1 IL) to assist in reducing circulation currents that might result from small differences in synchronization between primary subsystems 1000. Alternatively or in addition, each primary PDU 1251 may include a three-phase transformer to isolate PCDA 1250 from the respective primary subsystem 1000. The auxiliary PDU 2251 provides similar protection for the auxiliary subsystem 2000, but for DC power. For example, auxiliary PDU 2251 can include an energy buffer 204 (e.g., a capacitor) to buffer voltage fluctuations on the DC bus 415, e.g., due to switching of the primary converter 420. Alternatively or in addition, auxiliary PDU 2251 may include an isolated DC-DC converter, e.g., a dual-active-bridge (DAB) converter (e.g., configured similarly to auxiliary converter 430B in FIG. 1 IN), to isolate PCDA 1250 from auxiliary subsystem 2000. Since primary subsystems 1000 are not interconnected by IC modules, this particular embodiment of PCDA 1250 and energy system 100 provides a high degree of modularity as subsystems 1000 and 2000 can be disconnected from AC 410 and DC 415 buses, and new ones connected, straightforwardly.

[0358] FIG. 21C is a perspective view depicting an example embodiment of a PCDA 1250 interfacing with an energy system 100 configured for an EV. Energy system 100 and PCDA 1250 are configured similarly to the embodiment of FIG. 21B. In this case, energy system 100 includes six primary subsystems 1000-1 through 1000-6 with each phase PA, PB,and PC of the primary subsystems 1000 summing in parallel for providing three-phase power to motor(s) 1100 at a relatively high wattage. Here, LV auxiliary load 301 includes an auxiliary electrical system of the EV, and HV auxiliary load 303 includes an HVAC system of the EV.

[0359] Another example embodiment of a PCDA 1250 is described with respect to FIGs. 21D-21F which show a detailed layout of various components of the PCDA 1250. FIG. 21D is a perspective view depicting the exterior of PCDA 1250, FIG. 21E is a perspective view depicting the interior of PCDA 1250, and FIG. 21F is an exploded view of the components of PCDA 1250.

[0360] PCDA 1250 includes a housing 3050 having an upper portion 3051 and a lower portion 3052. As best seen in FIG. 21D, a variety of connectors are present on housing 3050, and each connector is for connection to the various, power, data, and / or control cable, wire, or fiber connections required by the devices interfacing through that connector. A first connector 3054 is for charging and provides power to and from charge port(s) 1102 and / or 1202 (or routing circuitry 1200 depending on the configuration). Connectors 3055 and 3058 can be for the provision of drive signals to a first EV auxiliary subsystem (e.g., active suspension for the left front wheel and right front wheel). Connectors 3056 and 3057 can be for the provision of drive signals to a second EV auxiliary subsystem (e.g., steer-by-wire for the left front wheel and right front wheel). Connector 3060 can be for the provision of auxiliary power (e.g., 12V, 24V, 48V, 60V, 500V) for use by other auxiliary loads of the EV (e.g., HVAC, onboard network, cabin lighting, etc.). Though one is shown here, multiple connectors 3060 can be used to provide various different voltages. Connector 3061 can be for the exchange of control signals and data with the vehicle ECU. Connector 3062 can be for the exchange of control signals and data with an ACD 3008.

[0361] As best seen in FIGs. 21E and 21F, PCDA 1250 includes various devices and cabling positioned in close proximity to each other, such that PCDA 1250 can act as a centralized hub for the routing of power and information within the EV. In this embodiment, PCDA 1250 includes MCD 112, ACD 3008 (e.g., an axle ECU), auxiliary drive 3015-1 (e.g., active suspension), auxiliary drive 3015-2 (e.g., steer-by-wire), and converter 3011 (e.g., a DC-DC converter for regulating down the auxiliary voltage from a DC bus 415). PCDA 1250 can also include multiple switches 1108 configured here as SSR relays 3022-1 and 3022-2 and electromechanical relays 3022-3 and 3022-4 for two separate motors. Connections 3023 between the switches 1108 and the charging connector 3054 are depicted as wire bundles but these can also be configured as (solid) bus bars in some embodiments. Bus bars can bepreferable for thermal management purposes due to acting as heatsinks for PCDA 1250 and allowing better airflow in PCDA 1250 when space is limited.Section 19: Bidirectional Capability Through Charge Port

[0362] The bidirectional capability provided by routing circuitry 1200 permits the charging and discharging of energy system 100 through the AC and / or DC charge port(s) 1102, 1202. The power output by energy system 100 can be in DC form, single-phase AC form, or multiphase AC form. As a result, an EV enabled with system 100 can be used to supply or transfer power from the EV to an externally located load or grid (the power consumption entity). The EV user can then be compensated in exchange for the supplied power, or can obtain other benefits such as the offloading of power to the user’s home during peak energy cost times to reduce utility costs. Such applications are generally referenced with different names depending on the type of consumption entity. For example, vehicle-to-grid (V2G) refers to instances where the EV is supplying power back to a power grid, vehicle-to- home (V2H) refers to instances where the EV is supplying power back to an energy network of a residence, vehicle-to-building (V2B) refers to instances where the EV is supplying power back to an energy network of a building or large loads therein, vehicle-to-community (V2C) refers to instances where the EV is acting as a source and sink for energy as a part of a larger surplus energy storage network in a community such as a city, and vehicle-to-vehicle (V2V) applications refers to instances where the EV is supplying power to other vehicles for energy distribution in a charging environment. Embodiments capable of practicing two or more of these applications can be referenced under broader headings such as vehicle-to-anything (V2A) and vehicle-to-everything (V2X).

[0363] Embodiments of energy system 100 configured for use in these applications have some common features. For example, control system 102 has the capability of communicating with an external energy controller (which may be local or remote to the EV), such that upon connection of control system 102 with the external energy controller, control system 102 can control the output of power through charge ports 1102 and / or 1202 to the external power consumption entity. This can entail disconnecting motor(s) 1100 from system 100 (e.g., with switches 1108), and instructing modules 108 to output power in a format (e.g., voltage, current, frequency, and / or phase) that matches the requirements of the power consumption entity, while at the same time maintaining balance (e.g., SOC and / or temperature) among sources 206 of modules 108.

[0364] The external controller has the responsibility for communicating energy requirements to system 100 (e.g., based on available power and price signals, in a format usable by system 100 such as voltage, current, frequency, and / or phase) and for managing the receipt of energy from system 100. The external controller may also be responsible for coordinating the energy inputs from other EVs if the application encompasses more than one. The responsibility for logging the amount of power injected by the EV, for purposes of financial payment or benefit to the EV operator in exchange for the power, can be with the external controller and / or control system 102. By way of non-limiting examples, the external controller may be a home energy management system (HEMS) or a Smart Home in the case of V2H, a Smart Building or Smart Garage in the case of V2B, a transmission or distribution grid controller (local or remote centralized) or an energy aggregator in the case of V2G and V2C, or a charge station in the case of V2V.

[0365] In an example embodiment using an EV having energy system 100 as a source of power, the power consumption entity has an associated power cable for receiving power from the EV. The power cable can be the same as a charge cable, with the external charge source 150 also acting as a local consumption entity interface for receiving power from the EV. Alternatively, the local consumption entity interface can be different from the external charge source 150. The user connects the applicable local interface to the EV through the power cable. The power cable is coupled to the applicable charge connector, having conductors for the charge port 1102, 1202 through which power will be transferred (e.g., DC, single phase AC, or multiphase AC). The power cable can also include a communication cable for transferring digital information between control system 102 and the external controller, which can be located in the local interface or can be remote. Control system 102 detects connection of the communication cable and negotiates with the external controller to identify the parameters for power transfer, including the voltage, current, frequency, and / or phase of the power signal. Other parameters can include the times during which to perform power transfer if on a schedule, the available power (or SOC) within system 100, demands to receive power, and confirmation of supply the same (if the application is on-demand as opposed to according to a schedule), demands to stop the supply of power, and the like. Power transfer can then occur according to the negotiated parameters. The local interface can also include a user interface (e.g., graphical user interface, display, user inputs, touchscreen, and the like) for notifying the user of the status of power transfer (e.g., on-going or stopped, power transfer history (e.g., number of kilowatts transferred), alerts, and the like).Section 20: Example Embodiments of Thermal Management Systems

[0366] The amount of heat generated by system 100 during operation can be significant. One or more thermal management systems can be utilized to circulate a heat transfer fluid (e.g., coolant, antifreeze, water, or a mixture thereof) in proximity with the various subsystems of system 100 and / or the motors and any other elements of an EV (or stationary system) that require cooling (or in some cases heating). FIG. 22A depicts an example of a thermal management system 3100 where coolant is pumped by a pump 3101 through various components of system 3100. The coolant can circulate such that the components with the greatest cooling requirements are cooled first and those with more relaxed thermal requirements are cooled last. For example, in this embodiment, pump 3101 circulates coolant first to battery modules 206 which may require coolant at a relatively low temperature between 20°C and 30°C, and then to electronics 3104, which may require coolant at a relatively higher temperature of up to 40°C or 50°C, and finally to one or more motors 1100 which may require coolant at a still higher temperature but preferably less than 60°C. Concerning a primary subsystem 1000 that includes multiple modules 108, electronics 3104 for a module 108 can include switching circuitry (e.g., S3-S6 or S1-S6) of converter 202, energy buffer 204, LCD 114, monitor circuitry 208 for the module 108, as well as a Battery Management System (BMS) for a battery 206 of the module 108. Concerning an auxiliary subsystem 2000 that includes multiple battery modules 206, electronics 3104 for a battery module 206 may include any peripheral circuitry associated with the battery module 206 such as monitor circuitry and a BMS. After circulating in close proximity to these components to cool them, the coolant can proceed through a heat exchanger 3108 where its temperature is brought down to a temperature close to the requirements of battery modules 206, at which point the coolant is again circulated through pump 3101 and the loop repeats.

[0367] Primary 1000 and auxiliary 2000 subsystems described herein can each be housed, respectively, within a common enclosure (or pack). FIG. 22B depicts an example of a common enclosure 3110 for a subsystem of energy system 100. Enclosure 3110 includes a bottom enclosure 3112, such as a base, and an opposing top enclosure 3111, such as a lid. For a primary subsystem 1000, enclosure 3110 can house each of its modules 108, as well as any interconnection modules 108IC that may be present in the primary subsystem 1000. The battery modules 206 and electronics 3104 of each module 108 are contained within enclosure 3110. Similarly, for an auxiliary subsystem 2000, enclosure 3110 can house each of its battery modules 206 and any electronics 3104 associated with the battery modules 206. In some embodiments, an enclosure 3110 may house multiple subsystems of energy system 100.For example, a common enclosure 3110 can house the modules 108 of two (or more) primary subsystems 1000 and any interconnection modules 108IC that may interconnect them such that a thermal management system 3100 is shared amongst the two (or more) primary subsystems 1000. Similarly, battery modules 206 and electronics 3104 of two (or more) auxiliary subsystems 2000 can also be housed in a common enclosure 3110 such that a thermal management system 3100 is shared amongst the two (or more) auxiliary subsystems 2000. In other embodiments, an enclosure 3110 may house portions of one or more subsystems of energy system 100. For example, each array 700 of a multiphase primary subsystem 1000 may be housed in a respective enclosure 3110 such that each array 700 has a dedicated thermal management system 3100. Similarly, each set 800 of battery modules 206 (e.g., FIGs. 1 IF- 11G) of an auxiliary subsystem 2000 may be housed in a respective enclosure 3110 such that each set 800 has a dedicated thermal management system 3100. Such situations can be appropriate when a large number of energy sources 206 and associated electronics 3104 are implemented in energy system 100, which generally involves a large number of thermal sources, as well as space constraints.

[0368] As shown in FIGs. 22C and 22D, both the top 3111 and bottom 3112 enclosures can each include a network of conduits 3222 or a network of bladders 3223 for conducting coolant through those aspects of the top 3111 and bottom 3112 enclosures to cool subsystems of energy system 100, which in this example is a primary subsystem 1000. Here, a conduit3114 primarily provides cooling to modules 108 of primary subsystem 1000 by convective heat transfer with a coolant, e.g., by circulating the coolant with a particular velocity and / or volumetric flow rate in proximity to battery modules 206 and / or electronics 3104 of the modules 108. On the other hand, a bladder 3115 primarily provides cooling to modules 108 of primary subsystem 1000 by conductive heat transfer with a coolant, e.g., by maintaining a relatively large volume of the coolant in proximity to battery modules 206 and / or electronics 3104 of the modules 108. A coolant-filled bladder 3115 acts as a thermal reservoir with a high heat capacity, therefore a large surface area and temperature gradient between a bladder3115 and a battery module 206 and / or electronics 3104 is advantageous to maximize heat transfer from these components. Adjacent bladders 3115 can be connected to one another via conduits such that coolant flows between bladders 3115, e.g., by advection, to help facilitate a uniform temperature distribution across the enclosure 3110.

[0369] Either of the conduit 3114 or bladder 3115 approaches can be implemented for different subsystems of energy system 100. In some cases, both approaches may be implemented within the same enclosure 3110. For example, a top enclosure 3111 can includea network of bladders 3223 and a bottom enclosure 3112 can include a network of conduits3222, or vice versa. As shown here, coolant from pump 3101 can be circulated to bottom enclosure 3112 where it passes through a network of conduits 3222 or bladders 3223, like that shown for top enclosure 3111, and thus passes in proximity to the battery modules 206 and cools them. The coolant can exit bottom enclosure 3112 and pass to top enclosure 3111 (either through a conduit external to the enclosure 3110 or via a conduit in the side of or within enclosure 3110), and circulate through another network of conduits 3222 or bladders3223, where it passes in proximity to the electronics 3104 and cools them. The coolant can then exit from top enclosure 3111 where it can proceed to the next component of the thermal management system 3100 such as motor(s) 1100.

[0370] FIG. 22E is a cross-section of an example embodiment of a module 108 of a primary subsystem 1000 positioned within an enclosure 3110. Here, electronics 3104 are positioned above the battery module 206 and are contained within an electronics housing 3122. Electronics 3104 are mounted on one or more substrates 3124 such as a printed circuit board (PCB) and / or insulated metal substrate (IMS) board that provides the electrical connections passing between the various components of the electronics 3104. Substrate 3124 is located immediately adjacent to a heatsink plate 3132-1 composed of a highly thermally conductive material, e.g., aluminum, aluminum alloy, copper, copper alloy, or steel.

[0371] In an EV implementation with an upper or a top orientation referring generally to positions closer to the passenger compartment of the EV (e.g., passenger-side) and a lower or bottom orientation referring generally to positions closer to a road or track (e.g., road-side or track-side), substrate 3124 is oriented above electronics 3104 such that the electronics 3104 are mounted in an upside-down or inverted fashion (e.g., with semiconductor power transistors located beneath the PCB or IMS to which they are soldered). This provides large surface area contact between substrate 3124 and heatsink 3132-1 and allows efficient dissipation of heat from electronics 3104 through substrate 3124 to heatsink 3132-1. Battery module 206 is located beneath housing 3122 and rests on the bottom enclosure 3112 with a second heatsink 3132-2 therebetween. Battery module 206 has positive and negative terminals 3128 located on the battery 206’s top. Electrical connections 3130 extend from terminals 3128 through (or alternatively exterior to) housing 3122 to substrate 3124 and / or to the converter 202 for switching. Connections 3130 can be configured as wire connections, but more preferably, are configured as bus bars. Bus bars can improve heat conduction away from electronics 3104 as well as increase airflow within housing 3122.

[0372] Top 3111 and bottom 3112 enclosures include conduit 3114 for conducting coolant 3136 (see FIG. 22C for example). Conduit 3114 can be composed of a highly thermally conductive material, e.g., aluminum, aluminum alloy, copper, copper alloy, or steel, and shaped with a polygonal cross-section as depicted here, although other shapes such as elliptical or circular or a combination of rounded and polygonal shapes can be used. Conduit 3114 is located within a channel 3120 in a top 3111 or bottom 3112 enclosure, the channel 3120 having a shape corresponding to the conduit 3114. For example, if conduit 3114 has a polygonal cross-section then channel 3120 can also have a polygonal crosssection to allow conduit 3114 to be located therein. Top 3111 and bottom 3112 enclosures can also be composed of a highly thermally conductive material, e.g., aluminum, aluminum alloy, copper, copper alloy, or steel. Channels 3120 can be machined or etched into top 3111 and bottom 3112 enclosures, and conduit 3114 can be press fit therein.

[0373] As shown here, two sections of conduit 3114 in top enclosure 3111 pass over the module 108, and three sections of conduit 3114 in bottom enclosure 3112 pass under the module 108. If desired, an interface layer 3134 can be present between the surfaces of conduits 3114 and a surface of a heatsink 3132. Interface layers 3134 can be composed of a material with high thermal conductivity and a degree of deformability or elasticity to form continuous and durable contact between heatsinks 3132 and the surfaces of conduit 3114 (as well as the surfaces of top 3111 and bottom 3112 enclosures). For example, an interface layer 3134 can be composed of a thermally conductive polymer that is relatively thinner than a heatsink 3132.

[0374] In this embodiment, multiple conduits 3114 are shown passing over and under one module 108, however, the density and layout of conduits 3114 will vary based on the thermal requirements of the application. While preferably at least one conduit 3114 passes over (and under) each module 108, such is not required. One conduit 3114 can be shared by two or more modules 108. Conduits 3114 can be routed over the center of the module 108 or can be at positions approximately one-third of the distance from the side of the module 108.

[0375] FIG. 22F is a cross-section of another example embodiment of a module 108 of a primary subsystem 1000 positioned within an enclosure 3110. This example embodiment is similar to that of FIG. 22E, except, instead of conduits 3114, top 3111 and bottom 3112 enclosures include bladders 3115 for conducting coolant 3136 (see FIG. 22D for example). Similar to a conduit 3114, a bladder 3115 can be composed of a highly thermally conductive material, e.g., aluminum, aluminum alloy, copper, copper alloy, or steel, and shaped with a polygonal cross-section as depicted here, although other shapes such as elliptical or circularor a combination of rounded and polygonal shapes can be used. Bladder 3115 is located within a cavity 3121 in a top 3111 or bottom 3112 enclosure, the cavity 3121 having a shape corresponding to the bladder 3115. For example, if bladder 3115 has a polygonal crosssection then cavity 3121 can also have a polygonal cross-section to allow bladder 3115 to be located therein. Cavities 3121 can be machined or etched into top 3111 and bottom 3112 enclosures, and bladders 3115 can be press fit therein.

[0376] As shown in FIG. 22F, no heatsinks 3132 are necessary for this embodiment as the bladders 3115 provide sufficient conductive heat transfer. A first bladder 3115-1 is positioned above the module 108 in the top enclosure 3111. The first bladder 3115-1 substantially covers the top surface of the substrate 3124 to provide a thermal reservoir for the electronics 3104. Similarly, a second bladder 3115-2 is positioned below the module 108 in the bottom enclosure 3112. The second bladder 3115-2 substantially covers the bottom surface of the battery module 206 to provide a thermal reservoir for the battery 206. Although not depicted in FIG. 22F, if desired, an interface layer 3134 can be present between a surface of first bladder 3115-1 and a surface of substrate 3124, as well as between a surface of second bladder 3115-2 and a surface of battery module 206.

[0377] In this embodiment, the top 3111 and bottom 3112 enclosures include a respective bladder 3115 for each module 108, however, the density and layout of bladders 3115 will vary based on the thermal requirements of the application. For example, top 3111 and bottom 3112 enclosures can include a network of bladders 3223 arranged such that each module 108 is covered by multiple (e.g., two, three, four, or more) bladders 3115. In a similar vein, the top 3111 and bottom 3112 enclosures can include a network of bladders 3223 arranged such that each bladder 3115 covers multiple (e.g., two, three, four, or more) adjacent modules 108. Different combinations of these network arrangements can also be used, for example, if an enclosure 3110 includes multiple different-sized modules 108.

[0378] In some embodiments, such as those depicted in FIGs. 23 A-23F, it is possible to provide coolant through only the top enclosure 3111 and cool all components of primary 1000 and auxiliary 2000 subsystems without first cooling the battery modules 206 and then subsequently cooling the electronics 3104. FIG. 23 A depicts another embodiment of thermal management system 3100 where coolant is circulated from pump 3101 to both the battery modules 206 and the associated electronics 3104 simultaneously, then passes to motor(s) 1100, and subsequently to heat exchanger 3108. As shown in the example embodiment of FIG. 23B, each subsystem of system 100 can be housed, respectively, in a common enclosure 3110 (or pack) having only a top enclosure 3111 configured for cooling. FIGs. 23 C and 23Ddepict example embodiments of enclosures 3110 for a primary subsystem 1000 similar to that of FIG. 22C and 22D, except coolant is conducted by a network of conduits 3222 or a network of bladders 3223 only within the top enclosure 3111. FIGs. 23E and 23F are crosssections depicting example embodiments of a module 108 of a primary subsystem 1000 positioned within an enclosure 3110 similar to that of FIGs. 22E and 22F, respectively, except the module 108 rests on a base 3126 and is provided cooling only from top enclosure 3111.

[0379] FIGs. 23G-23L depict additional embodiments for simultaneously cooling battery modules 206 and electronics 3104 which can be implemented, for example, using the thermal management system 3100 of FIG. 23 A. As shown in FIG. 23G, each subsystem of system 100 can be housed, respectively, in a common enclosure 3110 (or pack) having an intermediate panel 3113 configured for cooling. FIG. 23H depicts an example embodiment of an enclosure 3110 for a primary subsystem 1000 with intermediate panel 3113 positioned between battery modules 206 and electronics housings 3122 of each module 108. In this case, coolant is circulated within intermediate panel 3113 in proximity to both battery modules 206 and electronics 3104 housed within housings 3122. FIGs. 231 and 23 J depict example embodiments of intermediate panels 3113 configured with a network of conduits 3222 or a network of bladders 3223 for circulating coolant, similar to that of top 3111 or bottom 3112 enclosures (e.g., FIGs. 22C-22D).

[0380] FIGs. 23K and 23L are cross-sections depicting example embodiments of a module 108 of a primary subsystem 1000 positioned within an enclosure 3110 similar to that of FIGs. 23E and 23F, respectively, except coolant is conducted within intermediate panel 3113 between battery module 206 and electronics housing 3122. In this embodiment, electronics 3104 and substrate 3124 are in a non-inverted orientation to position electronics 3104 in closer proximity to intermediate panel 3113. Battery module 206 rests on a base 3126, substrate 3124 rests on intermediate panel 3113, and a lid 3125 covers a topmost surface of electronics housing 3122. An interface layer 3134 is positioned between intermediate panel 3113 and a topmost surface of battery module 206. Electrical connections 3130 extend through intermediate panel 3113 and interface layer 3134, around channels 3120 or cavity 3121, for communication between battery module 206 and electronics 3104. In this case, interface layers 3134 composed of thermally conductive polymer can be desirable for both improved heat transfer and to provide electrical isolation for terminals 3128 and connections 3130. To a similar effect, intermediate panel 3113 can be composed of a similar (or the same) thermally conductive polymer as interface layers 3134. Channels 3120 orcavities 3121 can be machined (or etched) into intermediate panel 3113 with conduits 3114 or bladders 3115, respectively, press fit therein. Holes or pathways can be drilled (or otherwise machined) into interface layers 3134 and intermediate panel 3113 for passage of connections 3130. While this cooling configuration may be more difficult to implement due to separating battery module 206 from housing 3122 and directing connections 3130 through intermediate panel 3113, it can provide efficient heat removal from module 108 as conduits 3114 or bladders 3115 are in thermal contact with both battery module 206 and electronics 3104.

[0381] The embodiments in FIGs. 23G-23L that provide cooling through intermediate panel 3113 can also be combined with the embodiments in FIGs. 22A-22F that provide cooling through both top 3111 and bottom 3112 enclosures, as well as the embodiments in FIGs. 23 A-23F that provide cooling through only top enclosure 3111. Different combinations of the enclosure 3110 configurations described herein can be utilized to meet the thermal requirements of a particular application. For example, modules 108 can be cooled within an enclosure 3110 having a top enclosure 3111, a bottom enclosure 3112, and an intermediate panel 3113 each configured with a network of conduits 3222 or a network of bladders 3223 such that coolant is conducted on both top and bottom surfaces of battery modules 206 and housing 3122. As another example, modules 108 can be cooled within an enclosure 3110 having a top enclosure 3111 and an intermediate panel 3113 each configured with a network of conduits 3222 or a network of bladders 3223 such that coolant is conducted on a top surface of battery modules 206 and both top and bottom surfaces of housing 3122. Heat sinks 3132 and interface layers 3134 can be present or absent between particular surfaces of modules 108 based on, for example, whether such surfaces are cooled via conduits 3114 or bladders 3115, the relative positions of the conduits 3114 or bladders 3115, and / or the thermal requirements of the particular application.

[0382] Note, while FIGs. 22A-23L have mainly been described with respect to modules 108 of a primary subsystem 1000, a similar configuration of battery modules 206 and any associated electronics 3104 can also be implemented for an auxiliary subsystem 2000. In cases where an auxiliary subsystem 2000 includes no associated electronics 3104 for its battery modules 206, the configurations in FIGs. 22A-23F remain the same and coolant can now be conducted on a top surface, a bottom surface, or both, of a battery module 206 without the need for an intermediate panel 3113. The embodiments of FIGs. 22A-23L also depict the electronics 3104 positioned above the battery module 206, but a reverse configuration can also be implemented, where the electronics 3104 are placed at the bottom of an enclosure 3110 and the battery module 206 is placed above the electronics 3104. In yetanother embodiment, the battery module 206 and electronics 3104 can be placed side-to-side and coolant can be conducted through a top 3111 and / or bottom 3112 enclosure. All the aforementioned variations can be implemented with coolant also passing through a network of conduits 3222 or bladders 3223 in a top, bottom, and / or sidewalls of an enclosure 3110.

[0383] Thermal management system 3100 can also be reconfigurable to provide optimized cooling based on the thermal output of the various components of energy system 100, exterior temperature and humidity, and / or the utilization of an air conditioning (AC) system, as well as to provide heating for the batteries 206 (or other energy sources 206).FIGs. 24A and 24B are block diagrams depicting an example embodiment of a reconfigurable thermal management system 3100 with the capability to cool or heat various components in a series or parallel fashion. Reconfigurability of system 3100 is provided by one or more valves that can selectively route liquid coolant through a variety of different paths. Control of the valves can be performed by control system 102 or by a different control device such as a vehicular ECU 104.

[0384] FIG. 24 A depicts thermal management system 3100 configured in a first state with two independent thermal management loops 3201 and 3202. First loop 3201 is configured for heating or cooling of battery modules 206 of a primary 1000 or auxiliary 2000 subsystem of energy system 100. Second loop 3202 is configured for cooling of respective electronics 3104 associated with the battery modules 206. For example, system 3100 can be a thermal management system dedicated to a single enclosure (or pack) within an EV. The independent loop configurations shown here permit independent management of the temperature of battery modules 206 and electronics 3104, as each can have different operating temperature ranges.

[0385] First 3201 and second 3202 loops each include various components interconnected by conduits of a heat transfer fluid (e.g., coolant) communication network 3205. First loop 3201 includes a pump 3204 for moving coolant through a heat exchanger 3208, a heater unit 3206, and then a network of conduits or bladders in close proximity to battery modules 206. Heater unit 3206 can be operated to raise the temperature of the coolant such that it performs a heating function to battery modules 206 in instances where battery modules 206 are below desired operating temperatures, such as when an EV is first started in a cold environment. (The term “coolant” is used for convenience, as coolant is a heat transfer fluid that can both cool and heat.) When used for heating, first loop 3201 can operate with heater unit 3206 activated and heat exchanger 3208 deactivated, and / or heat exchanger 3208can be bypassed via a bypass line 3211. Alternatively, first loop 3201 can be used for cooling battery modules 206, in which case heater unit 3206 can be deactivated (and / or bypassed with an optional bypass line 3207) and heat exchanger 3208 can be activated to cool the coolant as it is pumped through first loop 3201 by pump 3204. Second loop 3202 includes a pump 3210 for moving coolant through a network of conduits or bladders in close proximity to electronics 3104, then through a heat exchanger 3212 for cooling the coolant of second loop 3202. A bypass line 3215 can be used for times when heat exchanger 3212 is not required. Heat exchangers 3208 and 3212 can be different devices such as radiators of the EV or chillers associated with the AC system of the EV. Though not shown here, other components of energy system 100, such as PCDA 1250 and charge network distributor 3248, can be thermally managed with either first loop 3201 or second loop 3202.

[0386] FIG. 24B is a block diagram depicting thermal management system 3100 after valve reconfiguration to a second state with a serial coolant loop 3203 that cools both battery modules 206 and electronics 3104. In this example, heater unit 3206 remains in the loop 3203 after reconfiguration from the first state and can be deactivated (and / or bypassed with bypass line 3207) during cooling in the second state. First 3204 and second 3210 pumps operate to move coolant through the networks of conduits or bladders past battery modules 206 and electronics 3104. The coolant can take one of several different paths through serial coolant loop 3203 based on the cooling demands of battery modules 206 and / or electronics 3104. The coolant can be directed through both first heat exchanger 3208 and second heat exchanger 3212 to provide a relatively higher degree of temperature reduction to the coolant.Alternatively, the coolant can bypass either (or both) heat exchangers 3208 and 3212 as indicated by bypass lines 3211 and 3215, respectively. The decision to bypass one of the heat exchangers 3208 or 3212 can be based on, for example, whether the temperature of the coolant is such that only one heat exchanger is required to reduce the coolant’s temperature, or the current cooling capability of the various heat exchangers, such as whether a radiator will be able to provide adequate cooling given the outside temperature, or whether an AC unit chiller is cold enough to adequately chill the coolant given present demands on the AC system. The ability of thermal management system 3100 to be reconfigured between the first and second states (FIGs. 24A and 24B) provides a high degree of flexibility for cooling or heating energy system 100 under a wide variety of operating conditions. Moreover, other components of energy system 100, such as PCDA 1250 and charge network distributor 3248, can be thermally managed with serial coolant loop 3203 after reconfiguration to the second state.

[0387] FIG. 24C is a schematic diagram depicting an example embodiment of thermal management system 3100 as described with respect to FIGs. 24A and 24B. In this embodiment, a first network of conduits 3222-1 or bladders 3223-1 is located in close proximity to a first portion of a primary 1000 or auxiliary 2000 subsystem, e.g., battery modules 206, and a second network of conduits 3222-2 or bladders 3223-2 is located in close proximity to a second portion of the primary 1000 or auxiliary 2000 subsystem, e.g., electronics 3104. As shown at the bottom of FIG. 24C, various valves are shown that permit reconfigurability of system 3100, including a four- way valve 3231, a first three-way valve 3232, a second three-way valve 3233, and a gate valve 3234. Four-way valve 3231 is present between first network 3222-1 (or 3223-1) and pump 3204. Four-way valve 3231 can be placed in a first configuration to direct or route coolant from first network 3222-1 (or 3223-1) to first pump 3204 while at the same time directing coolant from either second heat exchanger 3212 or first three-way valve 3232 to second pump 3210. Four- way valve 3231 can be placed in a second configuration to direct coolant from first network 3222-1 (or 3223- 1) to second pump 3210 and to simultaneously direct coolant from second heat exchanger 3212 or first three-way valve 3232 to first pump 3204. First three-way valve 3232 can be used to direct coolant to second heat exchanger 3212 or bypass second heat exchanger 3212 via bypass line 3215. Second three-way valve 3233 can be used to direct coolant to first heat exchanger 3208 or bypass first heat exchanger 3208 via bypass line 3211. Gate valve 3234 can be used to prevent or permit the flow of coolant from first heat exchanger 3208 to heater unit 3206. If desired, a valve (e.g., a three-way valve) and a bypass line (e.g., bypass line 3207) can be implemented into communication network 3205 to selectively bypass heater unit 3206.

[0388] To configure this embodiment in the first state (FIG. 24A) with independent thermal management loops 3201 and 3202, four-way valve 3231 is placed in the first configuration to direct coolant from first network 3222-1 (or 3223-1) to pump 3204 and to direct coolant from heat exchanger 3212 or first three-way valve 3232 to pump 3210. This forms the first loop 3201 where coolant flows from first pump 3204 to second three-way valve 3233, and from there either to first heat exchanger 3208 or heater unit 3206, and from there to first network 3222-1 (or 3223-1) for cooling of, e.g., battery modules 206, and finally to four-way valve 3231 where the coolant path can repeat. If the coolant is routed to first heat exchanger 3208, then gate valve 3234 is opened to permit coolant flow, otherwise gate valve 3234 is closed. The second loop 3202 extends from second pump 3210 to second network 3222-2 (or 3223-2) for cooling of, e.g., electronics 3104, and then to first three-way valve3232 where the coolant can be routed either to second heat exchanger 3212 or to bypass line 3215, and finally to four- way valve 3231 where the coolant path can repeat.

[0389] To reconfigure this embodiment in the second state (FIG. 24B) with the serial coolant loop 3203, four-way valve 3231 is placed in the second configuration to direct coolant from first network 3222-1 (or 3223-1) to second pump 3210, where it flows to second network 3222-2 (or 3223-2) and then to first three-way valve 3232, where the coolant can be directed either to second heat exchanger 3212 or to bypass line 3215, and then back to fourway valve 3231. At this point the coolant is then directed to first pump 3204 and from there to second three-way valve 3233 where it can proceed to first heat exchanger 3208 or to bypass line 3211, and from there to (or around) heater unit 3206 and back to first network 3222-1 (or 3223-1), from where the coolant path can repeat.

[0390] In this embodiment, first heat exchanger 3208 can be a chiller associated with an AC system 3300 of the EV. First heat exchanger 3208 can run the coolant in close proximity with separate coolant of the AC system 3300 circulated through an independent heat transfer fluid (e.g., coolant) communication network 3241. The AC system 3300 is shown at the top of FIG. 24C, and includes a compressor 3242, from which AC system 3300 coolant flows to an exterior condenser 3244, to a thermal expansion valve (TXV) 3250, and from there to multiple gate valves 3245, 3247, and 3249 which permit or prevent the flow of coolant to an interior evaporator 3246, charge network distributor 3248, and first heat exchanger 3208, respectively.

[0391] Each of the gate valves 3245, 3247, and 3249 can be independently actuated based on the thermal requirements of the thermal management system 3100, for example, whether the AC system is in use to cool the passenger compartment via interior evaporator 3246, whether charge network distributor 3248 requires cooling, and / or whether three-way valve3233 is positioned to utilize first heat exchanger 3208.

[0392] While cooling of the one or more EV motor(s) can also be performed with thermal management system 3100, e.g., by integrating the motors into the cooling schematic of FIG. 24C, the one or more EV motors can also be cooled with an independent cooling system.FIG. 24D depicts an example embodiment of a thermal management system 3200 configured to cool two separate motors 1100-1 and 1100-2 of an EV. Here, thermal management system 3200 includes a pump 3254 which pumps coolant to PCDA 1250 and from there to motors 1100-1 and 1100-2. System 3200 can be configured to cool any number of one or more motors 1100, e.g., by placing them in parallel in the cooling schematic of FIG. 24D. Alternatively, multiple instances of system 3200 can be implemented, each cooling one ormore motors of the EV. Further, system 3200 can be configured to cool certain portions of energy system 100 associated with the motors, for instance PCDA 1250, as shown here, or alternatively charge network distributor 3248, or other components. Alternatively, thermal management system 3100 or AC system 3300 as described with respect to FIGs. 24A-24C can be configured to cool PCDA 1250, e.g., by integrating PCDA 1250 into the fluid communication network 3205 in series with second network 3222-2 (or 3223-2), or into the fluid communication network 3241 in series or parallel with charge network distributor 3248.

[0393] FIGs. 24E-24G are perspective views depicting an example embodiment of an enclosure 3110 having a primary subsystem 1000, a primary PDU 1251, and a portion of a reconfigurable thermal management system 3100 (e.g., FIGs. 24A-24D) housed therein. The primary subsystem 1000 includes three arrays 700-PA, 700-PB, and 700-PC of modules 108 for generating three-phase AC power ...

Claims

CLAIMS1. An energy system controllable to supply power to a plurality of loads, the energy system comprising: a primary subsystem coupled to an AC bus, the primary subsystem comprising one or more arrays, each array comprising a plurality of modules connected together to generate an AC voltage signal comprising a superposition of output voltages generated by each module of the array, wherein each module comprises: an energy source; and a converter connected to the energy source; an auxiliary subsystem coupled to a DC bus, the auxiliary subsystem comprising one or more energy sources connected together to generate a DC voltage signal; a primary converter connected to the AC and DC buses; and a control system communicatively coupled with the primary converter and each module of the primary subsystem, wherein the control system is configured to: control the converter of each module to generate the output voltage over a power connection for the module; and control the primary converter to convert AC power on the AC bus to DC power for the DC bus.

2. The energy system of claim 1, wherein: the converter of each module is configured to receive a charge signal over the power connection for the module, and the control system is further configured to: control the converter of each module to: (i) convert the charge signal into a continuous signal or a pulsed signal, and (ii) apply the continuous or pulsed signal to the energy source of the module.

3. The energy system of any preceding claim, wherein the energy source of each module is a battery module.

4. The energy system of any preceding claim, wherein the converter of each module is a DC-AC converter.

5. The energy system of claim 4, wherein the converter of each module is a fullbridge converter.

6. The energy system of any preceding claim, wherein each module further comprises: an energy buffer connected between the energy source and converter of the module.

7. The energy system of claim 6, wherein the energy buffer is a passive energy buffer.

8. The energy system of claim 7, wherein the passive energy buffer is a capacitor.

9. The energy system of claim 6, wherein the energy buffer is an active energy buffer.

10. The energy system of claim 9, wherein the active energy buffer comprises: a passive energy buffer; and one or more switches configured to selectively connect the passive energy buffer to the energy source and converter of the module.

11. The energy system of claim 10, wherein the passive energy buffer is a capacitor.

12. The energy system of any of claims 10-11, wherein the one or more switches are two-conductive position (TCP) switches or on / off switches.

13. The energy system of any of claims 10-12, wherein the control system is further configured to: control the one or more switches to selectively connect the passive energy buffer to the energy source and converter of the module.

14. The energy system of any preceding claim, wherein: the converter of each module is a first converter, the power connection for each module is a first power connection,each module further comprises: a second converter connected to the energy source, the second converter configured to receive a charge signal over a second power connection for the module, and the control system is further configured to: control the second converter of each module to: (i) convert the charge signal into a continuous signal or a pulsed signal, and (ii) apply the continuous or pulsed signal to the energy source of the module.

15. The energy system of claim 14, wherein the second converter of each module is unidirectional.

16. The energy system of claim 14, wherein: the second converter of each module is bidirectional, the output voltage of each module is a first output voltage, and the control system is further configured to: control the second converter of each module to generate a second output voltage over the second power connection of the module.

17. The energy system of any of claims 14-16, wherein the second converter of each module is a DC-DC converter comprising a transformer.

18. The energy system of claim 17, wherein the second converter of each module comprises a DC-AC converter connected between the second power connection and the transformer.

19. The energy system of claim 18, wherein the DC-AC converter is a full-bridge converter.

20. The energy system of any of claims 18-19 when also dependent on claim 15, wherein the second converter of each module further comprises a diode rectifier connected between the transformer and the energy source.

21. The energy system of any of claims 18-19 when also dependent on claim 16, wherein the second converter of each module further comprises an AC -DC converter connected between the transformer and the energy source.

22. The energy system of claim 21, wherein the AC -DC converter is a full-bridge converter or a push-pull converter.

23. The energy system of any preceding claim, wherein: the energy source of each module is a first energy source, and each module further comprises a second energy source connected to the first converter.

24. The energy system of claim 23, wherein the second energy source is connected to the first converter by an inductor.

25. The energy system of any of claims 23-24, wherein: the first energy source is a lithium-ion battery module of a first type, and the second energy source is a lithium-ion battery module of a second, different type.

26. The energy system of any of claims 23-24, wherein: the first energy source is a battery module, and the second energy source is a high energy density (HED) capacitor.

27. The energy system of any preceding claim, wherein: each module further comprises monitory circuity configured to: (i) monitor status information of the module, and (ii) output the status information to the control system; and the control system is configured to control the converters of the modules based on the status information.

28. The energy system of claim 27, wherein the status information comprises data characterizing a temperature and state of charge of each module.

29. The energy system of claim 28, wherein the control system is configured to control the converters of the modules to balance the temperature and state of charge of all modules of the primary subsystem.

30. The energy system of any preceding claim, wherein each energy source of the auxiliary subsystem is a battery module.

31. The energy system of any preceding claim, wherein the primary converter is unidirectional.

32. The energy system of any of claims 1-30, wherein: the primary converter is bidirectional, and the control system is further configured to: control the primary converter to convert DC power on the DC bus to AC power for the AC bus.

33. The energy system of any preceding claim, wherein the primary converter comprises: an AC -DC converter connected to the AC bus; and a DC-DC converter connected to the DC bus.

34. The energy system of claim 33, wherein the primary converter further comprises: a capacitor connected between the AC -DC and DC-DC converters.

35. The energy system of any of claims 33-34, wherein the AC -DC converter is a fullbridge converter.

36. The energy system of any of claims 33-35, wherein the primary converter further comprises: inductive interface circuitry connected between the AC bus and the AC -DC converter.

37. The energy system of claim 36, wherein the inductive interface circuity comprises one or more line filters.

38. The energy system of claim 37, wherein each line filter is an inductor.

39. The energy system of any of claims 33-38 when also dependent on claim 31, wherein the DC-DC converter is a DC-DC boost converter or a DC-DC buck converter.

40. The energy system of claim 39, wherein the DC-DC converter comprises a switch, a diode, an inductor, and a capacitor.

41. The energy system of any of claims 33-38 when also dependent on claim 32, wherein the DC-DC converter is a DC-DC boost-buck converter or a DC-DC buck-boost converter.

42. The energy system of claim 41, wherein the DC-DC converter comprises two switches, an inductor, and a capacitor.

43. The energy system of any preceding claim, wherein the control system comprises: a plurality of local control devices each configured to control the converters of one or more modules of the primary subsystem; and a main control device communicatively coupled with the local control devices and configured to control the primary converter.

44. The energy system of claim 43, wherein each local control device is configured to control a corresponding one of the modules of the primary subsystem.

45. The energy system of claim 44, wherein each module of the primary subsystem comprises a corresponding one of the local control devices.

46. The energy system of any preceding claim, wherein the primary subsystem comprises a plurality of arrays.

47. The energy system of claim 46, wherein each array comprises a same number of modules.

48. The energy system of any of claims 46-47, wherein the AC voltage signal generated by each array has a different phase angle.

49. The energy system of any of claims 46-48, wherein the AC bus comprises a respective node for each array of the primary subsystem.

50. The energy system of claim 49, further comprising: a charge port coupled to the AC bus and configured to conduct a charge source signal.

51. The energy system of claim 50, wherein the charge source signal is a multi -phase AC charge signal.

52. The energy system of claim 51, wherein the control system is further configured to: control the converters of the modules to charge the energy sources of the modules using the multi-phase AC charge signal on the AC bus; and control the primary converter to convert the multi-phase AC charge signal on the AC bus to DC power for the DC bus.

53. The energy system of claim 50, wherein the charge source signal is a DC charge signal or a single-phase AC charge signal.

54. The energy system of claim 53, further comprising: routing circuitry connected between the charge port and the AC bus, wherein the routing circuity is controllable to selectively route the DC or signal-phase AC charge signal to each node of the AC bus.

55. The energy system of claim 54, wherein: the control system is communicatively coupled with the routing circuitry, and the control system is further configured to: control the routing circuity to selectively route the DC or single-phase AC charge signal from the charge port to each node of the AC bus.

56. The energy system of claim 55, wherein the control system is further configured to:control the converters of the modules to charge the energy sources of the modules using the DC or single-phase AC charge signal on the AC bus; and control the primary converter to convert the DC or single-phase AC charge signal on the AC bus to DC power for the DC bus.

57. The energy system of claim 56, wherein the control system is further configured to: control the routing circuitry to cycle the DC charge signal routed to each node of the AC bus.

58. The energy system of claim 57, wherein the control system cycles the DC charge signal with a period of 1.5 milliseconds (ms) or less.

59. The energy system of any of claims 54-58, wherein the routing circuitry comprises a plurality of solid-state relay (SSR) circuits.

60. The energy system of claim 59, wherein each SSR circuit is a triac.

61. The energy system of claim 59, wherein each SSR circuit comprises one or more transistors.

62. The energy system of claim 61, wherein each transistor is an insulated gate bipolar transistor (IGBT).

63. The energy system of any of claims 59-62, wherein the routing circuitry further comprises a capacitor.

64. The energy system of any preceding claim, wherein the auxiliary subsystem comprises a plurality of energy sources.

65. The energy system of claim 64, wherein the energy sources of the auxiliary subsystem are connected in series.

66. The energy system of any preceding claim, wherein: the primary subsystem is a first primary subsystem of a plurality of primary subsystems each coupled to the AC bus.

67. The energy system of claim 66, further comprising: a plurality of primary power distribution units each connected between a corresponding one of the primary subsystems and the AC bus; and an auxiliary power distribution unit connected between the auxiliary subsystem and the DC bus.

68. The energy system of claim 67, wherein each of the primary and auxiliary power distribution units comprises one or more safety disconnection devices.

69. The energy system of claim 68, wherein each safety disconnection device is a fuse or a breaker.

70. The energy system of any of claims 67-69, wherein: each primary power distribution unit comprises a transformer, and the auxiliary power distribution unit comprises an isolated DC-DC converter.

71. The energy system of any of claims 66-70, further comprising: a plurality of enclosures each housing a corresponding one of the primary or auxiliary subsystems.

72. The energy system of claim 71 when also dependent on claim 67, wherein each enclosure further comprises a corresponding one of the primary or auxiliary power distribution units.

73. The energy system of any of claims 71-72, wherein each enclosure comprises: a plurality of conduits configured to conduct coolant; or a plurality of bladders configured to conduct coolant.

74. The energy system of any preceding claim, wherein: the plurality of loads comprises a primary load, and the AC bus is configured to supply power to the primary load.

75. The energy system of claim 74, further comprising: a plurality of switches connected between the primary load and the AC bus, wherein the plurality of switches are controllable to selectively connect the primary load to the AC bus.

76. The energy system of claim 75, wherein the plurality of switches are two- conductive position (TCP) switches or on / off switches.

77. The energy system of any of claims 75-76, wherein: the control system is communicatively coupled with the plurality of switches, and the control system is further configured to: control the plurality of switches to selectively connect the primary load to the AC bus.

78. The energy system of any of claims 74-77, wherein: the plurality of loads further comprises an auxiliary load, and the DC bus is configured to supply power to the auxiliary load.

79. The energy system of claim 78, further comprising: a DC-AC converter connected between the auxiliary load and the DC bus.

80. The energy system of claim 79, wherein: the control system is communicatively coupled with the DC-AC converter, and the control system is further configured to: control the DC-AC converter to convert DC power on the DC bus to AC power for the auxiliary load.

81. An electric vehicle comprising the energy system of any of claims 78-80, wherein: the primary load is coupled to the AC bus, the primary load comprising one or more motors of the electric vehicle; and the auxiliary load is coupled to the DC bus, the auxiliary load comprising an HVAC system of the electric vehicle.

82. The electric vehicle of claim 81 when also dependent on claim 71, wherein the enclosures housing each of the primary and auxiliary subsystems are arranged on a roof of the electric vehicle, within a chassis of the electric vehicle, or both.

83. The electric vehicle of any of claims 81-82, configured as an electric bus.

84. The electric vehicle of any of claims 81-82, configured as a rail-based electric vehicle.

85. The rail-based electric vehicle of claim 84, configured as an electric train or an electric tram.

86. A method for supplying power to the plurality of loads using the energy system of any of claims 78-80, the method comprising: coupling the primary load to the AC bus; coupling the auxiliary load to the DC bus; and supplying power from the primary and auxiliary energy systems to the AC and DC buses.

87. The method of claim 86, wherein supplying power from the primary and auxiliary energy systems to the AC and DC buses comprises: controlling, using the control system, the first converter of each module to generate the output voltage over the first power connection for the module; and controlling, using the control system, the primary converter to convert AC power on the AC bus to DC power for the DC bus.

88. The method of claim 87 when also dependent on claim 32, wherein supplying power from the primary and auxiliary energy systems to the AC and DC buses further comprises: controlling, using the control system, the primary converter to convert DC power on the DC bus to AC power for the AC bus.

89. The method of any of claims 87-88 when also dependent on claim 50, further comprising:applying the charge source signal to the charge port using a charge source; and charging the primary and auxiliary subsystems using the charge source signal.

90. The method of claim 89 when also dependent on claim 52, wherein charging the primary and auxiliary subsystems using the charge source signal comprises: controlling, using the control system, the converters of the modules to charge the energy sources of the modules using the multi-phase AC charge signal on the AC bus; and controlling, using the control system, the primary converter to convert the multiphase AC charge signal on the AC bus to DC power for the DC bus.

91. The method of claim 89 when also dependent on claim 56, wherein charging the primary and auxiliary subsystems using the charge source signal comprises: controlling, using the control system, the routing circuity to selectively route the DC or single-phase AC charge signal from the charge port to each node of the AC bus; controlling, using the control system, the converters of the modules to charge the energy sources of the modules using the DC or single-phase AC charge signal on the AC bus; and controlling, using the control system, the primary converter to convert the DC or single-phase AC charge signal on the AC bus to DC power for the DC bus.

92. The method of claim 91 when also dependent on claim 56, further comprising: controlling, using the control system, the routing circuitry to cycle the DC charge signal routed to each node of the AC bus.

93. The method of any of claims 89-92 when also dependent on claim 13, further comprising: controlling, using the control system, the one or more switches to disconnect the passive energy buffer from the energy source and first converter of the module.

94. The method of any of claims 86-93 when also dependent on claim 73, further comprising: conducting coolant through any of the of the conduits or bladders housed in the enclosures.

95. An energy system controllable to supply power to a load, the energy system comprising: one or more arrays, each array comprising a plurality of modules connected together to generate an AC voltage signal comprising a superposition of output voltages generated by each module of the array, wherein each module comprises: an energy source; a converter connected to the energy source; an energy buffer; and one or more switches controllable to selectively connect the energy buffer to the energy source and converter.

96. The energy system of claim 95, wherein the energy buffer is a capacitor.

97. The energy system of any of claims 95-96, further comprising: a control system communicatively coupled with each module, wherein the control system is configured to: control the converter of each module to generate the output voltage over a power connection for the module.

98. The energy system of claim 97, wherein: the converter of each module is configured to receive a charge signal over the power connection for the module, and the control system is further configured to: control the one or more switches of each module to disconnect the energy buffer from the energy source and converter of the module; and control the converter of each module to: (i) convert the charge signal into a pulsed signal, and (ii) apply the pulsed signal to the energy source of the module.

99. The energy system of any of claims 95-98, wherein the one or more arrays are a plurality of arrays.

100. The energy system of claim 99, further comprising: a charge port configured to conduct a DC charge signal or a single-phase AC charge signal; androuting circuitry connected between the charge port and the arrays, wherein the routing circuitry is controllable to selectively route the DC or single-phase AC charge signal to each of the arrays.

101. The energy system of claim 100, wherein the routing circuitry comprises a plurality of solid-state relay (SSR) circuits.

102. The energy system of claim 101, wherein the routing circuity further comprises a capacitor.

103. The energy system of any of claims 100-102 when also dependent on claim 98, wherein: the control system is communicatively coupled with the routing circuitry, and the control system is further configured to: control the routing circuity to selectively route the DC or single-phase AC charge signal from the charge port to each of the arrays.

104. The energy system of claim 103, wherein the control system is further configured to: control the routing circuitry to cycle the DC charge signal routed to each array.

105. The energy system of claim 104, wherein the control system cycles the DC charge signal with a period of 1.5 milliseconds (ms) or less.

106. An energy system controllable to supply power to a load, the energy system comprising: one or more arrays, each array comprising a plurality of modules connected together to generate an AC voltage signal comprising a superposition of output voltages generated by each module of the array, wherein each module comprises: an energy source; a converter connected to the energy source, the converter comprising a plurality of power transistors interconnected by a plurality of electrical connections; a substrate to which the power transistors are mounted thereon, the substrate comprising the electrical connections; anda housing supporting the power transistors between the energy source and substrate; and a plurality of bladders arranged across the substrates of the modules, the plurality of bladders configured to conduct coolant.

107. The energy system of claim 106, wherein the energy source of each module is a battery module.

108. The energy system of any of claims 106-107, wherein each module has a same size and shape.

109. The energy system of any of claims 106-108, wherein the housing of each module is positioned between the energy source and substrate of the module, the housing comprising the power transistors.

110. The energy system of any of claims 106-109, wherein each bladder is arranged across the substrate of a corresponding one of the modules.

111. The energy system of any of claims 106-110, wherein: the plurality of bladders is a first plurality of bladders; and the energy system further comprises a second plurality of bladders arranged across the energy sources of the modules, the second plurality of bladders configured to conduct coolant, wherein the modules are positioned between the first and second pluralities of bladders.

112. The energy system of claim 111, wherein each of the second plurality of bladders is arranged across the energy source of a corresponding one of the modules.

113. The energy system of any of claims 106-112, further comprising: an enclosure housing each of the modules and bladders.

114. The energy system of claim 113, wherein the enclosure comprises recesses supporting each of the bladders therein.

115. The energy system of any of claims 113-114, wherein the enclosure comprises a lid and a base.

116. The system of any of claims 113-115, wherein the enclosure further comprises a frame arranging the modules in a common plane, the frame comprising a plurality of struts extending between the modules.

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