Modular power converters
Modular power converters with cascaded H-bridge systems and bypass circuitry address space and reliability challenges in data centers, providing high power density and efficient power distribution with reduced downtime.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- SCALVY INC
- Filing Date
- 2025-10-14
- Publication Date
- 2026-04-23
AI Technical Summary
Large data centers require high power density solutions that minimize space usage while ensuring reliable power conversion and redundancy, with existing systems facing challenges in reducing filtering needs, voltage stress, and system downtime due to maintenance or fault conditions.
Implementing modular power converters with a multilevel cascaded H-bridge system, integrating AC and DC terminals in series and parallel configurations, and utilizing bypass circuitry for maintenance and fault handling, along with decentralized power management and smart integrated modules for efficient power distribution and redundancy.
Achieves high power density, reduces filtering needs, lowers voltage stress, and enables hot-swappable server trays with minimal downtime, enhancing reliability and space efficiency in data centers.
Smart Images

Figure US2025050777_23042026_PF_FP_ABST
Abstract
Description
Atty. Doc. No. SCLVY-100-C-WOMODULAR POWER CONVERTERSTECHNICAL FIELD
[0001] This disclosure relates to modular power converters.BACKGROUND
[0002] Large data centers require a lot of power, making the power conversion infrastructure an increasingly important task. Data racks typically utilize multiple power supply units connected to alternating current (AC) power and convert it to direct current (DC) power (e.g., 48V). Additionally, they often have BBU’s (battery backup units) to provide power when the input power has an interruption. This system has some limitations as the power needed for server racks continues to increase. Increasing power often requires an increase in space for the power conversion, leaving less room for the server racks.BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to-scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity.
[0004] FIG. 1 is a block diagram of an example of a system including a cascade of modular power converters used to supply power from an AC power source to a DC load.
[0005] FIG. 2 is a circuit diagram of an example of a modular power converter.
[0006] FIG. 3 is a block diagram of an example of a system including multiple cascades of modular power converters on respective phase legs of a multi-phase AC power line used to supply DC power.
[0007] FIG. 4 is a plot of an example of an AC voltage that is being converted to DC power using a cascade of modular power converters implementing a clamped, level-shifted control solution for AC-to-DC power conversion.
[0008] FIG. 5 is a plot of an example of AC signals for converting AC power to DC power using a modular power converter in a cascade of modular power converters that is implementinga phase shifted control solution for AC-to-DC power conversion.
[0009] FIG. 6 is a block diagram of an example of a cascaded multiphase power conversion system with a main controller configured to coordinate the operation of many modular power converters.
[0010] FIG. 7 is a flow chart of an example of a process for transferring power from an AC power source to a DC load using a collection of modular power converters.
[0011] FIG. 8 is a flow chart of an example of a process for transferring power from an AC power source to a DC load using a collection of modular power converters with back-up energy storage and magnetic isolation.
[0012] FIG. 9 is a block diagram of an example internal configuration of a processing apparatus that may be used to implement techniques described herein.
[0013] FIG. 10 is a flow chart of an example of a process for transferring power from an AC power source to a DC load using a collection of modular power converters arranged in a series cascade with respective bypass circuitries for the modular power converters.
[0014] FIG. 11 is a flow chart of an example of a process for transferring power from an AC power source to a DC load using a collection of modular power converters arranged in a series cascade with respective bypass circuitries for the modular power converters that are triggered based on detection of a fault condition occurring one of the modular power converters.
[0015] FIG. 12 is a flow chart of an example of a process for performing maintenance on a modular power converter arranged in a series cascade with respective bypass circuitries for the modular power converters. FIG. 1 is a block diagram of an example of a system including a cascade of modular power converters used to supply power from an AC power source to a DC load.
[0016] FIG. 13 is a block diagram of an example of a system including a cascade of modular power converters used to supply power from an AC power source to a DC load with bypass circuitry that may be used to handle fault conditions and to perform maintenance on a bypassed modular power converter without imposing down-time on the larger power converter system that is a part of.
[0017] FIG. 14A is a schematic of an example of a bypass circuitry including a mechanical switch.
[0018] FIG. 14B is a schematic of an example of a bypass circuitry including an electrical relay and a fault detection circuitry configured to control the relay.
[0019] FIG. 15 is a schematic diagram of a power conversion system in accordance with various implementations.
[0020] FIG. 16. depicts a charging and a discharging phase of a charge pump associated with power distribution system in accordance with various implementations.
[0021] FIG. 17 depicts an example of operation of a smart integrated module associated with the power distribution system in accordance with various implementations.
[0022] FIGS. 18-21 depict an example of a power supplying topology for one or more smart integrated modules and example operations associated with the one or more smart integrated modules in accordance with various implementations.
[0023] FIG. 22 depicts an example of a topology of a bidirectional DC-to-DC converter associated with one or more smart integrated modules in accordance with various implementations .
[0024] FIG. 23 depicts an example of a topology of a DC-to-DC converter associated with one or more smart integrated modules in accordance with various implementations.
[0025] FIG. 24 is a graphical representation illustrating an efficiency of one or more smart integrated modules in accordance with various implementations.
[0026] FIGS. 25 and 26 are schematic diagrams depicting the distribution of an AC load in accordance with various implementations.
[0027] FIG. 27 is a schematic diagram depicting the configuration of an electric load within a smart integrated module.
[0028] FIG. 28 depicts a configuration of one or more DC outputs associated with one or more smart integrated modules in accordance with various implementations.
[0029] FIG. 29 is a schematic diagram of another power distribution system in accordance with various implementations.
[0030] FIG. 30 is a schematic diagram of an example data center rack in accordance with various implementations.
[0031] FIG. 31 is a schematic diagram of a voltage doubler circuit in accordance with various implementations.DETAILED DESCRIPTIONOverview
[0032] Power conversion architectures and techniques using modular power converters aredescribed herein. In some implementations, the proposed architectures and techniques may utilize a multilevel cascaded H-bridge system to provide high power density. These systems may use a large number of modular power converters. For example, a modular power converter may have two stages. An input stage may convert AC power to a DC energy storage device (e.g., a capacitor or a battery). A second stage may convert the DC power to a steady, isolated DC power for server racks.
[0033] The modular power converters may have their AC input terminals arranged in series cascades between terminals of an AC power source, and may have their DC output terminals arrayed in parallel. The cascading of the AC voltage across the modular power converters may provide benefits over prior systems for power conversion, such as, for example, reducing filtering needs and the size and / or cost of electronic filtering circuitry, lowering voltage stress on electronic components in the modular power converters, reducing switching losses, enabling the use of smaller switching devices, distributed heat dissipation leading to compact thermal management needs, providing higher power factor and low total harmonic distortion (THD), lowering conduction losses across the switching devices due to smaller field effect transistor packages, and / or higher power density enabling the conservation of space in confined quarters (e.g., in a data center). Arraying the DC outputs of multiple modular power converters in parallel to support a DC load may enable the supply of high currents and / or make the current supply more robust to component failure via diversity / redundancy, which may decrease system downtime. The modular power converters may store back-up power using integrated energy storage devices (e.g., capacitors and / or batteries) in a distributed manner to achieve higher energy density. The modular power converters may provide electrical isolation to a DC load (e.g., one or more servers in a server rack). For example, transformers in the modular power converters may be used to provide electrical isolation. In the context of data centers, these power conversion architectures and techniques may enable a different type of rack architecture to generate the power consumed by the rack servers while minimizing the space used.
[0034] The AC terminals of the modular power converters may be configured for bypass to enable maintenance of individual modular power converters without system downtime and / or for safety in case of fault conditions in the modular power converters. In data centers, it is useful to be able to service the individual modular power converters. For example, the AC inputs of a modular power converter may be bypassed externally to a server tray containing the modular power converter in case of fault or maintenance so the modular power converter could be takenout while the system is capable of continuing operation by avoiding disrupting the current path during maintenance and to make the servers truly hot swappable. The system may include bypass circuitry for this purpose. In some implementations, the bypass circuitry includes mechanical components, such as a passive switch or a mechanical interlock that either automatically or manually shorts the positive and negative rails when a server tray is removed. For example, this may be implemented as a backplane connector having spring-loaded contacts that bridge the gap between the positive and negative AC rails when a server tray including the modular power converter is ejected. The backplane connector may be a normally closed interconnect that only opens when pushed by the server tray. In some implementations, the bypass circuitry includes a relay, solid-state switch, or hybrid (e.g., a fast solid state relay (SSR) and efficient relay) mounted on a server rack is activated when a modular power converter fails, and it provides a current path to the next server trays in the server rack. In such a solution, the whole tray may be be offline before its removal from the rack.
[0035] The modular power converters may be integrated into server trays due to their significantly higher power density, which, in some implementations, may exceed 250W / in3. When integrated into a server tray, the modular power converters may function as a power shelf, a capacitor shelf, and / or as a DC-to-DC converter. The modular power converters may be connected in a cascaded architecture to increase the power density, and reduce capacitor shelf sizing, while meeting power grid current slope requirements. By being integrated into server trays in a data center, the modular power converters may eliminate the need for a separate sidecar, translating to more space for processors (e.g., graphical processing units (GPUs)) and enhanced ecosystem compatibility. For example, a modular power converter may be integrated directly into a server / blade at a regulated 48-54 V DC. In some implementations, a small energy storage shelf within the modular power converter, between an AC-to-DC converter (e.g., a power factor converter (PFC) and a DC-to-DC converter (e.g., a regulated LLC converter) may be actively controlled to absorb load transients and smooth grid current variations (e.g., up to IkJ per server). In some implementations, a double AC feeder may be provided in accordance with overcurrent protection (OCP) requirements.
[0036] In some implementations, the proposed architectures and techniques may utilize a multilevel cascaded H-bridge system to provide high power density. These systems may use a large number of modular power converters. For example, a modular power converter may have two stages. An input stage may convert AC power to a DC energy storage device (e.g., acapacitor or a battery). A second stage may convert the DC power to a steady, isolated DC power for server racks.
[0037] Some implementations described herein include a system comprising: a plurality of electrically connected power supply units configured as smart integrated modules (SIMs), wherein each SIM electrically connects to an energy storage device and comprises at least one or more of the following: a bi-directional or uni-directional DC-to-AC power converter, a bidirectional or a uni-directional DC-to-DC power converter, a battery management module, and a local controller. One or more of the plurality of SIMs may further comprise one or more gate drivers configured to switch the DC-to-AC power converter on and off. The gate driver may be an isolated gate driver, a typical bootstrap gate driver, a charge pump gate driver, or any other type of gate driver.
[0038] An isolated gate driver may use electrical isolation between the input side and the output sides of the gate driver. This may entail the use of isolated voltage regulators, or isolated switching converters, leading to a higher cost and volume associated with the gate driver.
[0039] In a bootstrap gate driver, the bootstrap capacitor charging circuit may be dependent on the power converters’ switching. Thus, bootstrap capacitors may suffer at ultra-high or ultralow duty cycles. As such, these capacitors may not be suitable for an application provided by a power converter with ultra-high or ultra-low duty cycles.
[0040] A charge pump gate driver may use a similar bootstrap capacitor, however, the charging circuit of this capacitor is less dependent on the switching of the power converters. An external charging path may supply the bootstrap of the charge pump gate driver. This charging path includes supplying energy to an intermediate capacitor placed between the charge pump gate driver and the bootstrap capacitor using high-frequency switching. Consequently, the intermediate capacitor may discharge energy by charging the bootstrap capacitor periodically, even at ultra-high or ultra-low duty cycles.
[0041] Some implementations provide a system for decentralized power management, the system comprising: a shared communication pool; and a plurality of electrically connected power supply units configured as SIMs, wherein each of the plurality of SIMs is configured to communicate through the shared communication pool; wherein each of the plurality of SIMs are further configured to: organize the power flow of an electrically connected energy storage device associated with each of the plurality of SIMs in an ascending, or a descending, order based on the local data associated with each of the plurality of SIMs and their correspondent energystorage devices; wherein each of the plurality of SIMs are further configured to determine one or more control operations based on one or more measurements and / or estimations; wherein the one or more control operations include data acquisition, network-aware decision-making, autonomous execution, or a combination thereof; and wherein the one or more measurements are based on local measurements of each of the plurality of SIMs and its associated electrically connected energy storage device or remote measurements of the other SIMs among the plurality of SIMs and their associated electrically connected energy storage devices. For example, the one or more measurements or estimations may include a temperature, a current, a voltage, a state of charge estimation, a state of health estimation, a state of life estimation, a degradation estimation, or a combination thereof.
[0042] Some implementations may provide a system comprising: a plurality of electrically connected power supply units configured as SIMs, wherein each of the SIMs is configured to receive, or send, power through one or more power converters disposed within each of the SIMs from a transformer; wherein the one or more power converters are connected to a secondary side of the transformer, and wherein power flows between the power converters and their electrically connected energy storage devices, of each of the plurality of SIMs; wherein the primary side of the transformer comprises at least one AC-to-DC rectifier circuit and at least one high switching circuit; wherein sending or receiving power through the one or more power converters may comprise simultaneously balancing the local measurements and estimations of the electrically connected energy storage devices such as the state of charge, the state of health, the state of life, the degradation, or a combination thereof. The plurality of the SIMs may be further configured to charge a subset of the energy storage devices and decouple another subset of energy storage devices based on the storage devices measurements and estimations. Every energy storage device from the subset of the decoupled energy storage devices may be configured to balance its internal energy storage elements (e.g., cells of a battery module) while decoupled from the charging path. The system can recouple the decoupled subset of energy storage devices to the plurality of the energy storage devices; and decouple another subset of energy storage devices based on measurements and / or estimations, associated with the storage devices, from the plurality of energy storage devices. Each of the plurality of SIMs can further include a DC-to- DC converter in a parallel / series network; wherein one side of the DC-to-DC converter is connected to a DC load and another side of the DC-to-DC converter is connected to an energy storage device; wherein each of the plurality of SIMs is configured to magnetically or opticallyisolate the energy storage device from the DC load; wherein each of the plurality of SIMs may be configured to balance an energy storage device via a DC load; wherein the energy storage device may be balanced via remote or local control; wherein each of the plurality of SIMs may be configured to adjust a method of control associated with each of the plurality of SIMs to maintain a maximum system efficiency.
[0043] Some implementations may provide a system for selectively charging or discharging the plurality of energy storage devices associated with a plurality of electrically connected power supply units, the system comprising the plurality of electrically connected power supply units configured as SIMs, wherein each of the SIMs is configured to: either electrically connect its associated energy storage device to a charging or a discharging path, or bypass its associated energy storage device from a charging or a discharging path based on some, or any, of the following: comparing its associated energy storage device state of charge with the state of charge of other energy storage devices associated with other SIMs in the series string, comparing the temperature of the energy storage device associated with the SIM with the temperature of other energy storage devices or SIMs, or a faulty condition with the SIM or its associated energy storage device. A frequency with which a first electrically connected power supply unit of the electrically connected power supply units is placed in a current discharge path is determined based on comparing a state of charge associated with the first electrically connected power supply unit with a state of charge associated with a second electrically connected power supply unit of the electrically connected power supply units; remove the second electrically connected power supply unit from a charging path while simultaneously charging based on the state of charge associated with the second electrically connected power supply unit; remove an electrically connected power supply unit of the electrically connected power supply units based on a temperature of the electrically connected power supply unit; or remove the electrically connected power supply unit based on a malfunction associated with the electrically connected power supply unit; and wherein the state of charge of the second electrically connected power supply unit is higher than a state of charge of the first electrically connected power supply unit.
[0044] Some implementations may provide a system comprising: a plurality of electrically connected power supply units configured as SIMs, wherein each of the SIMs include a plurality of electrical sources and a plurality of electrical loads in a network of series-connected power converters; and wherein each of the plurality of electrically connected power supply units areconfigured to produce multiple voltage outputs while simultaneously splitting a current associated with an energy storage device.
[0045] Some implementations may provide a system comprising: a plurality of electrically connected power supply units configured as SIMs, wherein each of the SIMs include a DC-to- DC converter; wherein one side of the DC-to-DC converter is electrically connected to the SIM’s associated energy storage device, while the secondary side of the DC-to-DC converter is electrically connected in parallel, series or a combination thereof with the secondary sides of the DC-to-DC converters of the other SIMs to produce one or more DC voltage output at different voltage levels to different DC networks associated with the system; wherein AC power is connected to the DC power terminals (e.g., high-voltage DC power terminals) and transmits power to an energy storage device associated with each of the plurality of electrically connected power supply units; wherein each of the plurality of electrically connected power supply units further includes at least one transformer; and wherein an energy storage device associated with each of the plurality of electrically connected power supply units is separated from an electrical load or an electrical source associated with each of the plurality of electrically connected power supply units.
[0046] Some implementations may provide a system comprising: a housing that comprises a plurality of energy storage units, a plurality of data center loads, and a plurality of electrically connected power supply units, wherein: the plurality of electrically connected power supply units is configured as a plurality of SIMs that are electrically connected to each other, and wherein each SIM of the plurality of SIMs is electrically connected to each energy storage unit of the plurality of energy storage units; and each energy storage unit of the plurality of energy storage units is configured to distribute electrical power to each data center load of the plurality of data center loads; wherein each SIM of the plurality of SIMs includes at least one of a bidirectional or uni-directional DC-to-AC power converter, a bi-directional or a uni-directional DC-to-DC power converter, a battery management module, and a local controller; wherein each SIM of the plurality of SIMs comprises one or more gate drivers configured to switch the bidirectional or the uni-directional DC-to-AC power converter on and off, and wherein the one or more gate drivers can be configured as an isolated gate driver, a bootstrap gate driver, or a charge pump gate driver; wherein each SIM of the plurality of SIMs is adjacently disposed in relation to each energy storage unit of the plurality of energy storage units; wherein each SIM of the plurality of SIMs is further configured to have a separate DC output that is connected to aseparate data center load of the plurality of data center loads; wherein each SIM of a first plurality of SIMs is further configured to connect a DC output bus associated with each SIM of the first plurality of SIMs in parallel or in series with a DC output bus associated with each SIM of a second plurality of SIMs; wherein each data center load of the plurality of data center loads is electrically connected to the DC output bus associated with each SIM of the first plurality of SIMs or the DC output bus associated with each SIM of the second plurality of SIMs at an output of each SIM of the plurality of SIMs; wherein each data center load of the plurality of data center loads is configured to: accept the electrical power at an isolated DC-to-DC converter; and reduce a voltage level to a predefined level to provide the reduced voltage level to a printed circuit board, wherein each data center load of the plurality of data center loads includes the printed circuit board; wherein each SIM of the plurality of the SIMs has a regulating DC-to-DC converter connected between each energy storage unit of the plurality of energy storage units and each data center load of the plurality of data center loads; further comprising a voltage doubler circuit, wherein the voltage doubler circuit is configured to increase a voltage level at an AC power side associated with each SIM of the plurality of SIMs; further comprising one or more uninterrupted power supply units configured to use the same energy storage unit from the plurality of energy storage units in a power conversion process from a grid associated with each data center load of the plurality of data center loads; wherein each SIM of the plurality of SIMs is further configured to control one or more local variables, in an associated battery energy storage and in the SIM while performing one or more power conversions, and wherein the one or more local variables includes a state of charge, a temperature, a state of health, or a combination thereof; wherein each SIM of the plurality of SIMs is further configured to balance the state of charge of one or more associated modules based on a switching sequence in relation to the plurality of the SIMs; wherein each SIM of the plurality of the SIMs communicates with the plurality of the SIMs or a central controller to determine the switching sequence; and wherein each SIM of the plurality of the SIMs balances the state of charge of one or more cells of each SIM of the plurality of SIMs while performing one or more system functionalities.
[0047] As used herein, the term “circuitry” refers to an arrangement of electronic components (e.g., transistors, resistors, capacitors, and / or inductors) that is structured to implement one or more functions. For example, a circuit may include one or more transistors interconnected to form logic gates that collectively implement a logical function.Details
[0048] FIG. 1 is a block diagram of an example of a system 100 including a cascade of modular power converters used to supply power from an AC power source 102 to a DC load 104. The system 100 includes multiple modular power converters, a first modular power converter 110 and a second modular power converter 120, arranged in a cascade with their AC input terminals in series with the AC power source 102, and with their DC output terminals arranged in parallel with each other and the DC load 104. This cascaded arrangement of the modular power converters may be used to reduce the voltage stress of each converter's components and provide for lower harmonics, while using their DC outputs in parallel may provide high current loads and / or redundancy. Systems using this architecture for power conversion may achieve higher power density than conventional power converter architectures. For example, the system 100 may be used to implement the process 700 of FIG. 7. For example, the system 100 may be used to implement the process 800 of FIG. 8.
[0049] The system 100 includes a first AC -to-DC converter 112 with AC terminals connected in series with multiple AC -to-DC converters (e.g., including the AC -to-DC converter 122) between terminals of an AC power source 102. For example, the AC power source may be an AC power line from a power grid or another AC voltage source device. For example, the first AC -to-DC converter 112 may include a single-phase power factor correction (PFC) circuitry. In some implementations, the first AC-to-DC converter 112 includes an isolation component (e.g., including a transformer). In some implementations, the first AC-to-DC converter 112 includes four switches connected in an H-bridge topology. For example, the four switches may be metal- oxide-semiconductor field-effect transistors (MOSFETs). For example, the first AC-to-DC converter 112 may include the transistors QI, Q2, Q3, and Q4 of the input stage 210 of FIG. 2. For example, the first AC-to-DC converter 112 may include the transistors QI, Q2, Q3, and Q4 of the modular power converter 334 of FIG. 3.
[0050] The system 100 includes a first energy storage device 114 connected to DC terminals of the first AC-to-DC converter 112. In some implementations, the first energy storage device 114 is a capacitor (e.g., an electrolytic capacitor or a super capacitor). In some implementations, the first energy storage device 114 is a battery (e.g., a lithium-ion battery, a nickel-metal hydride (NiMH) battery, or a solid-state battery).
[0051] The system 100 includes a first DC-to-DC converter 116 with input terminals connected to the first energy storage device 114, wherein output terminals of the first DC-to-DC converter 116 are connected in parallel with multiple DC-to-DC converters (e.g., including theDC-to-DC converter 126) between terminals of a DC load 104. In some implementations, the DC load 104 includes a server installed in a server rack. For example, the system 100 may be installed in a data center. In some implementations, the first DC-to-DC converter 116 includes an isolation component. For example, the isolation component of the first DC-to-DC converter 116 may include a transformer (e.g., the transformer 234). In some implementations, the first DC-to-DC converter 116 is a regulated LLC converter. The first DC-to-DC converter 116 may include a resonant tank that allows for zero voltage switching (ZVS) or zero current switching (ZCS), reducing switching losses and improving efficiency, especially over a wide range of operating conditions. For example, the first DC-to-DC converter 116 may include the output stage 230 of FIG. 2.
[0052] In this example, the first AC -to-DC converter 112, the first energy storage device 114, and the first DC-to-DC converter 116 are components of a first modular power converter 110, which may be contained within a housing that exposes the AC terminals of the first AC -to- DC converter 112 and the output terminals of the first DC-to-DC converter 116. In some implementations, the first AC -to-DC converter 112, the first energy storage device 114, and the first DC-to-DC converter 116 are components of a first modular power converter 110 that are mounted on a circuit board along with a first controller of the first modular power converter 110 that is configured to control switching in the first AC-to-DC converter 112 and in the first DC- to-DC converter 116. For example, the first controller may include a processing apparatus (e.g., a processor or a microcontroller with one or more ports configured to drive gate voltages of switches in the first AC-to-DC converter 112 and in the first DC-to-DC converter 116. For example, the first controller may include the processing apparatus 900 of FIG. 9.
[0053] In some implementations, the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter 112 are also components of respective modular power converters (e.g., including the modular power converter 120) with components that match the components of the first modular power converter 110. For example, the AC power source 102 may be one phase leg of a multi-phase AC power line, and AC power on another phase leg of the multi -phase AC power line is also converted using a series cascade of modular power converters with components that match the components of the first modular power converter 116, wherein output terminals of respective DC-to-DC converters in the series cascade of modular power converters are connected in parallel with the output terminals of the first DC-to- DC converter 116. For example, the AC power source 102 may be one of the phase legs in thethree-phase AC power line 310, and the first modular power converter 110 may be the modular power converter 334 in the system 300 of FIG. 3.
[0054] The operation of the modular power converters, including the first modular power converter 110 and the second modular power converter 120, arranged in a cascade may be configured and / or coordinated by a main or central controller (e.g., the main controller 614 of FIG. 6). This main controller may be implemented using a processing apparatus (e.g., the processing apparatus 900 of FIG. 9), which may be configured to transmit control signals to the first controller and respective controllers of the respective modular power converters that include the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter, to cause the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter 112 to coordinate to convert AC power from the AC power source 102 to energy stored in the first energy storage device 114 and respective energy storage devices (e.g., including the energy storage device 124) of the respective modular power converters (e.g., including the modular power converter 120). In some implementations, the processing apparatus commands the first controller and respective controllers of the respective modular power converters to implement a phase shifted control solution for AC-to-DC power conversion. For example, the phase shifted control solution for AC-to-DC power conversion may operate as described in relation to FIG. 5. In some implementations, the processing apparatus commands the first controller and respective controllers of the respective modular power converters to implement a clamped, level-shifted control solution for AC-to-DC power conversion. For example, the clamped, level-shifted control solution for AC-to-DC power conversion may operate as described in relation to FIG. 4.
[0055] FIG. 2 is a circuit diagram of an example of a modular power converter 200. The modular power converter 200 includes an input stage 210, a capacitor 220, which serves as an energy storage device, and an output stage 230.
[0056] The input stage 210 includes an AC-to-DC converter with a H-bridge topology (including the transistors QI, Q2, Q3, and Q4). The input stage 210 receives AC power via its AC terminals 202, which may be connected in series with other AC-to-DC converters between the terminals of an AC power source.
[0057] The capacitor 220 serves as an energy storage device. For example, the capacitor may be an electrolytic capacitor or a super capacitor, among other types of capacitors that could be used.
[0058] The output stage 230 includes a DC-to-DC converter. The output stage 230 includes a transformer 234, which may be used to provide isolation to a DC load. The DC output terminals 204 may be connected in parallel with the DC output terminals of multiple modular power converters to provide a DC load with high current and / or redundancy.
[0059] Although not shown explicitly in FIG. 2, the modular power converter 200 may include a local controller configured to drive the gate voltages of the switches (QI through QI 6) in accordance with a power conversion scheme, such as the clamped, level-shifted control solution for AC-to-DC power conversion described in relation to FIG. 4 or the phase shifted control solution for AC-to-DC power conversion described in relation to FIG. 5. For example, the local controller may be implemented using the processing apparatus 900 of FIG. 9.
[0060] FIG. 3 is a block diagram of an example of a system 300 including multiple cascades of modular power converters on respective phase legs of a multi-phase AC power line used to supply DC power. In this example, modular power converters with their respective AC-to-DC converters, having an H-bridge topology, and arranged in a series cascade for each phase of a three-phase AC power line 310. Since this is a multi-phase embodiment, the phase legs (312, 314, and 316) are connected together at the bottom of the cascades to make a neutral point 318. The system 300 includes a cascade of modular power converters on a first phase leg 312 of the three-phase AC power line 310, including a first modular power converter 330, a second modular power converter 332, and a third modular power converter 334. Note that more modular power converters may be included in the cascade, connected in series between the first modular power converter 330, a second modular power converter 332. The system 300 also includes a cascade of modular power converters on a second phase leg 314 of the three-phase AC power line 310, including a fourth modular power converter 340. The system 300 also includes a cascade of modular power converters on a third phase leg 316 of the three-phase AC power line 310, including a fifth modular power converter 350.
[0061] The three-phase AC power line 310 will provide power to the respective energy storage devices (e.g., an AC-link or input capacitor), which may provide a DC bus with an AC ripple. The second stages of the modular power converters will take the DC bus and provide isolation to DC loads 320 (e.g., one or more servers in a data center requiring a DC power bus with a DC voltage in the range of 48V to 51V). In some implementations, the DC-to-DC conversion may utilize three phases in a balanced manner on any given DC output bus to reduce the required output capacitance via destructive interference of AC ripple from the three phaseson the shared DC output bus. More or fewer phases can be used to provide the DC output power.
[0062] FIG. 4 is a plot of an example of an AC voltage 400 that is being converted to DC power using a cascade of modular power converters implementing a clamped, level-shifted control solution for AC-to-DC power conversion. The AC voltage 400 is a multi-level AC voltage signal that is generated as a superposition of voltages across the terminals of the cascade of modular power converters. The AC voltage 400 is approximating a sinusoidal AC voltage waveform from an AC power source (e.g., a phase leg of a multi-phase AC power line) with terminals that the cascade of modular power converters is connected between. For example, the AC voltage 400 may be superposition of voltages across respective energy storage devices (e.g., capacitors or batteries) of the modular power converters in the cascade, which are selectively connected to the cascade (e.g., selectively connected using switches of an AC-to-DC converter arranged in an H-bridge topology). In some implementations, the respective energy storage devices are intermittently clamped to generate the AC voltage 400 that is approximating a sinusoidal AC voltage waveform to keep harmonic distortion in the AC-to-DC power converters low.
[0063] FIG. 5 is a plot of an example of a set of AC signals 500 for converting AC power to DC power using a modular power converter in a cascade of modular power converters that is implementing a phase shifted control solution for AC-to-DC power conversion. For a phase shifted control solution, the modular power converters arranged in a cascade will provide outputs in a synchronized manner that when superimposed will provide the necessary output voltage of the AC power source (e.g., a phase leg of a multi-phase AC power line). For example, this solution may have a phase difference for each modular power converter’s output which would provide an interleaving output to minimize harmonic distortion. In some implementations, this type of solution is not clamped and thus would have less need for a larger energy storage component. Another important aspect of this type of switching is that it would enable modular power converters to provide even power sharing since the modular power converters will provide a similar duty cycle throughout the AC input sinewave. Through additional controls, modular power converters can have adjustments to their respective duty cycles to further the power sharing capability, while making sure the AC link voltage stays within parameters. For example, phase shifted control solution for AC-to-DC power conversion may utilize pulse width modulation (PWM) techniques to approximate the line voltage from the AC power source.
[0064] The set of AC signals 500 includes four phases of a triangle wave for synchronization, each of which may be generated for a corresponding modular power converter in a cascade of four. The four triangle wave control signals are shown in the top plot of FIG. 5, with the sinusoidal AC power source voltage overlaid on the same plot. In this example, the four triangle wave control signals run at ten times the frequency of the sinusoidal AC power source voltage. The phase shifts between the four triangle wave control signals are 90 degrees. The set of AC signals 500 includes the voltage across the AC terminals for each of the four modular power converters in the series cascade between the terminals of the AC power source, which are shown in the four middle plots of FIG. 5. The voltage across the AC terminals of one of the modular power converters may be selectively switched (e.g., using a full-bridge topology between the AC terminals) between three states: positive voltage, zero voltage (i.e., short circuit), and negative voltage. The positive and negative voltage states may be achieved by selectively coupling the AC terminals to an energy storage device (e.g., a capacitor or a battery) of the modular power converter with the desired polarity. The operation of the modular power converters in the cascade may be synchronized using the triangle wave control signals by comparing the triangle wave control signal for a modular power converter to the sinusoidal AC power source voltage in order to derive gate voltages for controlling the state transitions of the that modular power converter. For example, when the sinusoidal AC power source voltage is positive, the voltage across the AC terminals for each of the four modular power converters in the series cascade may be selectively alternated between the positive state and the zero state in order to collectively generate the multi-level AC voltage (as shown in the bottom plot of FIG. 5) to approximately match the sinusoidal AC power source voltage. In some implementations, when the triangle wave control signal assigned to a modular power converter is below the sinusoidal AC power source voltage, that modular power converter is put in the positive state, and, when the triangle wave control signal assigned to a modular power converter is above the sinusoidal AC power source voltage, that modular power converter is put in the zero state. For example, when the sinusoidal AC power source voltage is negative, the voltage across the AC terminals for each of the four modular power converters in the series cascade may be selectively alternated between the negative state and the zero state in order to collectively generate the multi-level AC voltage (as shown in the bottom plot of FIG. 5) to approximately match the sinusoidal AC power source voltage. In some implementations, when the triangle wave control signal assigned to a modular power converter is above the sinusoidal AC power source voltage,that modular power converter is put in the negative state, and, when the triangle wave control signal assigned to a modular power converter is below the sinusoidal AC power source voltage, that modular power converter is put in the zero state.
[0065] Various techniques may be used to evenly distribute stress across the circuit components in the cascade of modular power converters. For example, the phases / triangle wave control signals assigned to the modular power converters may be rotated between periods of the sinusoidal AC power source voltage. In some implementations, fast and slow legs in an AC-to-DC converter topology (e.g., as in the input stage 210) may be rotated in order to age the switches evenly.
[0066] FIG. 6 is a block diagram of an example of a cascaded multiphase power conversion system 600 with a main controller 614 configured to coordinate the operation of many modular power converters. The system 600 may be configured to receive AC electrical power from an AC power source, such as an electrical grid 602. The AC power is represented by an AC voltage660 labeled as VAC and one or more AC currents labeled as ii, i , ... IM, such as the AC current661 (ii), where M indicates the number of phases of the multiphase AC power, for example 3, 6, or 12 phases. The power conversion system 600 converts the AC power to a DC power, represented by a DC current 667 (IDC) at a positive output terminal 678 and a DC voltage 664 (VDC) across the positive output terminal 678 and a negative output terminal 680. Although power equals voltage multiplied by current, this disclosure may reference only a voltage or a current when describing a corresponding power. For example, this disclosure may simply state that the power conversion system 600 converts the AC voltage 660 to the DC voltage 664, which should be understood as a proxy for the power conversion system 600 converting AC power to DC power. The DC power output by the power conversion system 600 may be regulated and / or isolated from the AC power source. The DC power may be delivered to a load 612, or in some cases, to multiple loads, such as loads 1-L, where the loads may have similar or different power needs and electrical characteristics. In some implementations, the load 612 comprises computing devices of a data center, such as servers, switches, storage arrays, network routers, firewalls, or other information technology infrastructure equipment.
[0067] The power conversion system 600 comprises M > 1 sets of N > 1 power supply modules, with each phase 604 of the AC power coupled to a respective set 606 of power supply modules. The set 606 is an example of one of the sets of power supply modules, and the power supply module 608 is an example of an individual power supply module. Note that in someimplementations, there may be more phases than sets or fewer phases than sets, and further, the number of power supply modules in each set may differ between sets. In a simplified configuration where N = 1 , the power conversion system 600 reduces to a non-cascaded system with a single power supply module. In a configuration where N > 1, each set comprises at least two power supply modules connected in a cascade. For example, with N = 6, the positive power supply terminal 610 of the first power supply module of the cascade (labeled “1,1” in FIG. 6) is connected to the AC power supply and the negative power supply terminal 618 of the first power supply module is connected to the positive power supply terminal of the second power supply module (labeled “2,1” in FIG. 6). The cascaded connection continues in this manner for N = 3, 4, and so on. For any configuration N > 1, the power conversion system 600 may be configured to convert single-phase or multiphase AC power to DC power. In other words, and single power supply module may be configured to convert either single phase AC power (M = 1) or multiphase AC power (M > 1, e.g., M = 3 for 3-phase power) to DC power.
[0068] The power conversion system 600 comprises a controller, such as the main controller 614, that is configured to send one or more control signals 616 to the power supply modules, such as the power supply module 608. The main controller 614 may be implemented by the processing apparatus 900 of FIG. 9. A control signal may be any combination of electrical switching actions, analog signals, digital signals, and / or programmatic command instructions, and can be transmitted over a suitable conductor or medium, a data bus (e.g., a CAN bus), or via other standard or proprietary communication links.
[0069] The main controller 614 is configured to coordinate operation of the power conversion system 600, including managing timing and control across the power supply modules, such as synchronizing startup and shutdown sequences and enabling safe power transfer. As described later herein, the main controller 614 may send one or more of the control signals 616 to an input stage of a power supply module to electrically isolate the AC power from an energy storage device of the power supply module to enable precharge or discharge of the energy storage device by a DC power supply. In some implementations, the main controller 614 commands respective local controllers of the modular power converters to implement a phase shifted control solution for AC-to-DC power conversion. For example, the phase shifted control solution for AC-to-DC power conversion may operate as described in relation to FIG. 5. In some implementations, the main controller 614 commands respective local controllers of the modular power converters to implement a clamped, level-shifted control solution for AC-to-DC powerconversion. For example, the clamped, level-shifted control solution for AC-to-DC power conversion may operate as described in relation to FIG. 4.
[0070] FIG. 7 is a flow chart of an example of a process 700 for transferring power from an AC power source to a DC load using a collection of modular power converters. The process 700 includes converting 710 AC power to DC power using a series cascade of modular power converters; and supplying 720 DC power to a DC load using DC outputs of the modular power converters connected in parallel. For example, the process 700 may be implemented using the system 100 of FIG. 1. This cascaded arrangement of the modular power converters may be used to reduce the voltage stress of each converter's components and provide for lower harmonics, while using their DC outputs in parallel may provide high current loads and / or redundancy. This technique for power conversion may achieve higher power density than conventional power conversion techniques. For example, the process 700 may be implemented using the modular power converter 200 of FIG. 2. For example, the process 700 may be implemented using the system 300 of FIG. 3. For example, the process 700 may be implemented using the system 600 of FIG. 6.
[0071] The process 700 includes converting 710 AC power to DC power using a series cascade of modular power converters. Various power conversion schemes may be used to coordinate the operation of multiple modular power converters connected in series to collectively convert a relatively large AC voltage into DC power. In some implementations, converting 710 AC power to DC power using the series cascade of modular power converters includes implementing a phase shifted control solution for AC-to-DC power conversion. For example, the phase shifted control solution for AC-to-DC power conversion described in relation to FIG. 5 may be used to covert a large AC voltage into DC power. In some implementations, converting 710 AC power to DC power using the series cascade of modular power converters comprises implementing a clamped, level-shifted control solution for AC-to-DC power conversion. For example, the clamped, level-shifted control solution for AC-to-DC power conversion described in relation to FIG. 4 may be used to covert a large AC voltage into DC power. These power conversion schemes may be implemented in part using software running local controllers for each of the modular power converters and / or a main or central controller. For example, a local controller and / or a main or central controller may be implemented using the processing apparatus 900 of FIG. 9.
[0072] The process 700 includes supplying 720 DC power to a DC load using DC outputs ofthe modular power converters connected in parallel. In some implementations, the DC load includes a server installed in a server rack. For example, the process 700 may be used in a data center to supply power to racks of servers while achieving high power density to conserve space. The high degree of parallelism may provide robustness to component failure and decrease server down-times.
[0073] FIG. 8 is a flow chart of an example of a process 800 for transferring power from an AC power source to a DC load using a collection of modular power converters with back-up energy storage and magnetic isolation. The process 800 includes converting 810 AC power to DC power using a series cascade of modular power converters; storing 820 back-up power for the DC load in respective capacitors of the modular power converters; providing 830 isolation to the DC load using respective transformers of the modular power converters; and supplying 840 DC power to a DC load using DC outputs of the modular power converters connected in parallel. This technique for power conversion may achieve higher power density than conventional power conversion techniques. For example, the process 700 may be implemented using the modular power converter 200 of FIG. 2. For example, the process 700 may be implemented using the system 300 of FIG. 3. For example, the process 700 may be implemented using the system 600 of FIG. 6.
[0074] The process 800 includes converting 810 AC power to DC power using a series cascade of modular power converters. Various power conversion schemes may be used to coordinate the operation of multiple modular power converters connected in series to collectively convert a relatively large AC voltage into DC power. In some implementations, converting 810 AC power to DC power using the series cascade of modular power converters includes implementing a phase shifted control solution for AC-to-DC power conversion. For example, the phase shifted control solution for AC-to-DC power conversion described in relation to FIG. 5 may be used to covert a large AC voltage into DC power. In some implementations, converting 810 AC power to DC power using the series cascade of modular power converters comprises implementing a clamped, level-shifted control solution for AC-to-DC power conversion. For example, the clamped, level-shifted control solution for AC-to-DC power conversion described in relation to FIG. 4 may be used to covert a large AC voltage into DC power. These power conversion schemes may be implemented in part using software running local controllers for each of the modular power converters and / or a main or central controller. For example, a local controller and / or a main or central controller may be implemented using theprocessing apparatus 900 of FIG. 9.
[0075] The process 800 includes storing 820 back-up power for the DC load in respective energy storage devices of the modular power converters. The multiple modular power converters may include respective energy storage devices (e.g., the first energy storage device 114), and this stored back-up power may be distributed across these respective energy storage devices. Distributing the energy storage in this manner may serve to increase the energy density of the collective energy storage system for a DC load (e.g., including one or more servers in a server rack). In some implementations, the process 800 includes storing 820 back-up power for the DC load in respective capacitors of the modular power converters. The back-up energy may be stored 820 in capacitors (e.g., electrolytic capacitors or super capacitors) of the modular power converters. In some implementations, the process 800 includes storing 820 back-up power for the DC load in respective batteries of the modular power converters. The back-up energy may be stored 820 in various types of batteries, such as, for example, lithium-ion batteries, nickel-metal hydride (NiMH) batteries, or solid-state batteries.
[0076] The process 800 includes providing 830 isolation to the DC load using respective transformers of the modular power converters. For example, modular power converters may include respective transformers (e.g., the transformer 234) in their respective DC-to-DC converters.
[0077] The process 800 includes supplying 840 DC power to a DC load using DC outputs of the modular power converters connected in parallel. The high degree of parallelism may provide robustness to component failure and decrease server down-times. In some implementations, the DC load includes a server installed in a server rack. For example, the process 800 may be used in a data center to supply power to racks of servers while achieving high power density to conserve space.
[0078] FIG. 9 is a block diagram of an example internal configuration of a processing apparatus 900 that may be used to implement techniques described herein. The processing apparatus 900 may be, be similar to, include, or be included in an apparatus for performing one or more methods, processes, algorithms, operations, tasks, and / or techniques, as described herein. The processing apparatus 900 may be, be similar to, include, or be included in a main controller or a local controller of a power conversion system. The processing apparatus 900 includes a bus 902 that interconnects various components or units, such as a processor 904, a memory 906, a power source 908, an input component 910, an output component 912, and acommunication component 914, among other examples.
[0079] The processor 904 may include one or more chiplets, chips, system-on-chips (SoCs), network-on-chips (NoCs), chipsets, packages, or devices that individually or collectively constitute or include a processing system. The processing system includes a processor (or “processing”) circuitry in the form of one or multiple processors, microprocessors, processing units (such as CPUs), GPUs, neural processing units (NPUs) and / or digital signal processors (DSPs), processing blocks, application-specific integrated circuits (ASIC), programmable logic devices (PLDs) (such as field programmable gate arrays (FPGAs)), or other discrete gate or transistor logic or circuitry (all of which may be generally referred to herein individually as “processors” or collectively as “the processor” or “the processor circuitry”). The processor 904 may include a cache, or cache memory, for local storage of operating data or instructions.
[0080] One or more of the processors may be individually or collectively configurable or configured to perform various operations described herein. In some implementations, a single processor may perform all of the operations described as being performed by the one or more processors. In some implementations, a group of processors collectively configurable or configured to perform a set of operations may include a first set of (one or more) processors configurable or configured to perform a first operation of the set and a second processor configurable or configured to perform a second operation of the set, or may include the group of processors all being configured or configurable to perform the set of operations. The first set of processors and the second set of processors may be the same set of processors or may be different sets of processors.
[0081] The memory 906 includes one or more memory components, which may each be volatile memory or non-volatile memory, that individually or collectively constitute a memory system. The memory system may include memory circuitry in the form of one or more memory devices, memory blocks, memory elements or other discrete gate or transistor logic or circuitry, each of which may include tangible storage media such as random-access memory (RAM) or read-only memory (ROM), or combinations thereof (all of which may be generally referred to herein individually as “memories” or collectively as “the memory,” “the memory system,” or “the memory circuitry”). The memory 906 may include non- transitory memory, transitory memory, or a combination thereof. Volatile memory may include RAM (e.g., a dynamic RAM (DRAM) module, such as a double data rate (DDR) synchronous DRAM (SDRAM)). Nonvolatile memory may include a disk drive, a solid state drive, flash memory, or phase-changememory. In some implementations, the memory 906 may be distributed across multiple devices. For example, the memory 906 may include network-based memory or memory in multiple clients or servers performing the operations of those multiple devices. The memory 906 may be referred to as one or more computer-readable storage media. A computer-readable storage medium may include any storage unit (or multiple storage units) that store data or instructions that are readable by a processing system. A computer-readable storage medium may include, for example, at least one of a data repository, a data storage unit, a computer memory, a hard drive, a disk, or a random access memory.
[0082] One or more of the memories may be coupled (for example, operatively coupled, communicatively coupled, electronically coupled, or electrically coupled) with one or more of the processors and may individually or collectively store processor-executable instructions (e.g., code such as software) that, when executed by one or more of the processors, may configure or otherwise cause one or more of the processors to perform various functions or operations described herein. “Software” shall be construed broadly to mean instructions, instruction sets, code, code segments, program code, programs, subprograms, software modules, applications, software applications, software packages, routines, subroutines, objects, executables, threads of execution, procedures, and / or functions, among other examples, whether referred to as software, firmware, middleware, microcode, hardware description language, or otherwise.
[0083] In some implementations, the executable instructions may include application data or an operating system, among other examples. The executable instructions may include one or more application programs, which may be loaded or copied, in whole or in part, from nonvolatile memory to volatile memory to be executed by the processor 904. For example, the executable instructions may include instructions for performing techniques described in this disclosure. In some implementations, the application data may include functional programs, such as computational programs, analytical programs, or database programs, among other examples. The operating system may be, for example, Microsoft Windows®, Mac OS X®, or Linux®; an operating system for a mobile device, such as a smartphone or tablet device; or an operating system for a non-mobile device, such as a mainframe computer.
[0084] Reference to “one or more memories” should be understood to refer to any one or more memories of a corresponding device, such as the memory described in connection with FIG. 9. For example, operation described as being performed by, or data described as being stored on, one or more memories can be performed by, or stored on, respectively, the samesubset of the one or more memories or different subsets of the one or more memories. Additionally or alternatively, in some examples, one or more of the processors may be preconfigured to perform various functions or operations described herein without requiring configuration by software. For example, the memory 906 may include data or instructions that are hard-wired into the processing system.
[0085] In the description herein, language describing a system, an apparatus, or a device as taking an action (such as performing, determining, initiating, receiving, calculating, deciding, computing, processing, etc.) is to be understood as describing that some appropriate component, module, or unit of the system, apparatus, or device is taking the action. As used herein, the terms “component,” “module,” and “unit” are intended to be broadly construed as hardware and / or a combination of hardware and software.
[0086] The power source 908 provides power to the processing apparatus 900. For example, the power source 908 may be an interface to an external power distribution system, e.g., an electrical grid. As an example, the power source 908 may be a battery, such as where the processing apparatus 900 is a mobile device or is otherwise configured to operate independently of an external power distribution system. In some implementations, the processing apparatus 900 may include or otherwise use multiple power sources. In some such implementations, the power source 908 can be a backup battery.
[0087] The input component 910 and / or the output component 912 may include one or more input interfaces and / or output interfaces configured for facilitating communication between the processing apparatus 900 and one or more peripheral devices such as, for example, one or more sensors, detectors, displays, input devices, or other devices configured for facilitating interaction with the processing apparatus 900 or the environment around the processing apparatus 900. An input device may, for example, include a positional input device, such as a mouse, touchpad, touchscreen, or the like; a keyboard; or another suitable human or machine interface device. An output device may, for example, include a display, such as a liquid crystal display, a cathode -ray tube, a light emitting diode display, or other suitable display. In some implementations, the peripherals devices may include a geolocation component, such as a GPS location unit. In some examples, the peripheral devices may include a temperature sensor for measuring temperatures of components of the processing apparatus 900, such as the processor 904.
[0088] The communication component 914 may include an interface for facilitating a connection or link to a network. The communication component 914 may include a wirednetwork interface or a wireless network interface. The processing apparatus 900 may communicate with other devices via the communication component 914 using one or more network protocols, such as using a Controller Area Network (CAN), Ethernet, TCP, IP, power line communication, an IEEE 802.X protocol (e.g., Wi-Fi, Bluetooth, or ZigBee), infrared, visible light, general packet radio service (GPRS), global system for mobile communications (GSM), code-division multiple access (CDMA), Z-Wave, a cellular communication protocol, another protocol, or a combination thereof. For example, the processing apparatus 900 can communicate with a database server.
[0089] The communication component 914 may include a transceiver, which may include a transmitter or a receiver. In some configurations, one or a combination of antenna(s), modem(s), multiple input multiple output (MIMO) detectors, receive processors, transmit processors, and / or the transmit MIMO processors may be included in the transceiver. The transceiver may be under control of or used by one or more processors, and in some respects in conjunction with processor-readable code stored in the memory, to perform aspects of the methods, processes, techniques, and / or operations described herein.
[0090] FIG. 10 is a flow chart of an example of a process 1000 for transferring power from an AC power source to a DC load using a collection of modular power converters arranged in a series cascade with respective bypass circuitries for the modular power converters. The process 1000 includes converting 1010 AC power to DC power using a series cascade of modular power converters; supplying 1020 DC power to a DC load using DC outputs of the modular power converters connected in parallel; bypassing 1030 one of the modular power converters in the series cascade of modular power converters by shorting AC terminals of the bypassed modular power converter; and continuing 1040 to supply DC power to the DC load using DC outputs of the modular power converters, excepting the bypassed modular power converter. For example, the process 1000 may be implemented using the system 1300 of FIG. 13. This cascaded arrangement of the modular power converters may be used to reduce the voltage stress of each converter's components and provide for lower harmonics, while using their DC outputs in parallel may provide high current loads and / or redundancy. This technique for power conversion may achieve higher power density than conventional power conversion techniques. The bypass of individual modular power converters in the series cascade may be used recover from fault conditions occurring in a modular power converter and / or to perform maintenance on a modular power converter without causing down- time for the larger power conversion system. Forexample, the process 1000 may be implemented using the modular power converter 200 of FIG. 2. For example, the process 1000 may be implemented using the system 300 of FIG. 3. For example, the process 1000 may be implemented using the system 600 of FIG. 6.
[0091] The process 1000 includes converting 1010 AC power to DC power using a series cascade of modular power converters. Various power conversion schemes may be used to coordinate the operation of multiple modular power converters connected in series to collectively convert a relatively large AC voltage into DC power. In some implementations, converting 1010 AC power to DC power using the series cascade of modular power converters includes implementing a phase shifted control solution for AC-to-DC power conversion. For example, the phase shifted control solution for AC-to-DC power conversion described in relation to FIG. 5 may be used to covert a large AC voltage into DC power. In some implementations, converting 1010 AC power to DC power using the series cascade of modular power converters comprises implementing a clamped, level-shifted control solution for AC-to-DC power conversion. For example, the clamped, level-shifted control solution for AC-to-DC power conversion described in relation to FIG. 4 may be used to covert a large AC voltage into DC power. These power conversion schemes may be implemented in part using software running local controllers for each of the modular power converters and / or a main or central controller. For example, a local controller and / or a main or central controller may be implemented using the processing apparatus 900 of FIG. 9.
[0092] The process 1000 includes supplying 1020 DC power to a DC load using DC outputs of the modular power converters connected in parallel. In some implementations, the DC load includes a server installed in a server rack. For example, the process 1000 may be used in a data center to supply power to racks of servers while achieving high power density to conserve space. The high degree of parallelism may provide robustness to component failure and decrease server down-times.
[0093] The process 1000 includes bypassing 1030 one of the modular power converters in the series cascade of modular power converters by shorting AC terminals of the bypassed modular power converter. For example, the bypassed modular power converter may be bypassed 1030 using a mechanical switch (e.g., the mechanical switch 1410). In some implementations, the mechanical switch is external to a server tray containing the bypassed modular power converter and the mechanical switch is configured to automatically bypass 1030 the bypassed modular power converter when the server tray is removed from a server rack. For example, thebypassed modular power converter may be bypassed 1030 using an electrical relay (e.g., the relay 1460), an electrical contactor, or a solid-state switch.
[0094] The process 1000 includes continuing 1040 to supply DC power to the DC load using DC outputs of the modular power converters, excepting the bypassed modular power converter. After the bypassed modular power converter has been bypassed 1030, then its AC terminals are shorted together, thus allowing the remaining modular power converters in the series cascade of modular power converters to continue 1040 converting 1010 AC power to DC power and supplying DC power to the DC load. This bypass mode arrangement may be used to avoid down-time for the larger power conversion system.
[0095] In some implementations, the process 1000 also includes providing isolation to the DC load using respective transformers of the modular power converters. In some implementations, the process 1000 also includes storing back-up power for the DC load in respective capacitors of the modular power converters. In some implementations, the process 1000 also includes storing back-up power for the DC load in respective batteries of the modular power converters.
[0096] FIG. 11 is a flow chart of an example of a process 1100 for transferring power from an AC power source to a DC load using a collection of modular power converters arranged in a series cascade with respective bypass circuitries for the modular power converters that are triggered based on detection of a fault condition occurring one of the modular power converters. The process 1100 includes converting 1110 AC power to DC power using a series cascade of modular power converters; supplying 1120 DC power to a DC load using DC outputs of the modular power converters connected in parallel; detecting 1128 a fault condition in one of the modular power converters; responsive to detection of the fault condition, bypassing 1130 one of the modular power converters in the series cascade of modular power converters by shorting AC terminals of the bypassed modular power converter; and continuing 1140 to supply DC power to the DC load using DC outputs of the modular power converters, excepting the bypassed modular power converter. For example, the process 1100 may be implemented using the system 1300 of FIG. 13. This cascaded arrangement of the modular power converters may be used to reduce the voltage stress of each converter's components and provide for lower harmonics, while using their DC outputs in parallel may provide high current loads and / or redundancy. This technique for power conversion may achieve higher power density than conventional power conversion techniques. The bypass of individual modular power converters in the series cascade responsiveto detection of fault conditions in those modular power converters may serve to improve safety and / or reduce down-time for a larger power conversion system. For example, the process 1100 may be implemented using the modular power converter 200 of FIG. 2. For example, the process 1100 may be implemented using the system 300 of FIG. 3. For example, the process 1100 may be implemented using the system 600 of FIG. 6.
[0097] The process 1100 includes converting 1110 AC power to DC power using a series cascade of modular power converters. Various power conversion schemes may be used to coordinate the operation of multiple modular power converters connected in series to collectively convert a relatively large AC voltage into DC power. In some implementations, converting 1110 AC power to DC power using the series cascade of modular power converters includes implementing a phase shifted control solution for AC-to-DC power conversion. For example, the phase shifted control solution for AC-to-DC power conversion described in relation to FIG. 5 may be used to covert a large AC voltage into DC power. In some implementations, converting 1110 AC power to DC power using the series cascade of modular power converters comprises implementing a clamped, level-shifted control solution for AC-to-DC power conversion. For example, the clamped, level-shifted control solution for AC-to-DC power conversion described in relation to FIG. 4 may be used to covert a large AC voltage into DC power. These power conversion schemes may be implemented in part using software running local controllers for each of the modular power converters and / or a main or central controller. For example, a local controller and / or a main or central controller may be implemented using the processing apparatus 900 of FIG. 9.
[0098] The process 1100 includes supplying 1120 DC power to a DC load using DC outputs of the modular power converters connected in parallel. In some implementations, the DC load includes a server installed in a server rack. For example, the process 1100 may be used in a data center to supply power to racks of servers while achieving high power density to conserve space. The high degree of parallelism may provide robustness to component failure and decrease server down-times.
[0099] The process 1100 includes detecting 1128 a fault condition in one of the modular power converters. For example, fault detection circuitry (e.g., including one or more voltage sensors and / r current sensors) integrated in a modular power converter may be integrated in the modular power converter and used to generate a control signal for a relay to short the AC terminals of the modular power converter when a fault condition is detected. For example, afault condition may occur when a current or voltage in the modular power converter is outside of an acceptable range (e.g., a rated range for components of the modular power converter).
[0100] The process 1100 includes, responsive to detection of the fault condition, bypassing 1130 one of the modular power converters in the series cascade of modular power converters by shorting AC terminals of the bypassed modular power converter. For example, the bypassed modular power converter may be bypassed 1130 using a mechanical switch (e.g., the mechanical switch 1410). In some implementations, the mechanical switch is external to a server tray containing the bypassed modular power converter and the mechanical switch is configured to automatically bypass 1130 the bypassed modular power converter when the server tray is removed from a server rack. For example, the bypassed modular power converter may be bypassed 1130 using an electrical relay (e.g., the relay 1460), an electrical contactor, or a solid- state switch.
[0101] The process 1100 includes continuing 1140 to supply DC power to the DC load using DC outputs of the modular power converters, excepting the bypassed modular power converter. After the bypassed modular power converter has been bypassed 1130, then its AC terminals are shorted together, thus allowing the remaining modular power converters in the series cascade of modular power converters to continue 1140 converting 1110 AC power to DC power and supplying DC power to the DC load. This bypass mode arrangement may be used to avoid down-time for the larger power conversion system.
[0102] In some implementations, the process 1100 also includes providing isolation to the DC load using respective transformers of the modular power converters. In some implementations, the process 1100 also includes storing back-up power for the DC load in respective capacitors of the modular power converters. In some implementations, the process 1100 also includes storing back-up power for the DC load in respective batteries of the modular power converters.
[0103] FIG. 12 is a flow chart of an example of a process 1200 for performing maintenance on a modular power converter arranged in a series cascade with respective bypass circuitries for the modular power converters. FIG. 1 is a block diagram of an example of a system including a cascade of modular power converters used to supply power from an AC power source to a DC load. The process 1200 includes performing 1210 maintenance on the bypassed modular power converter after bypassing the bypassed modular power converter. For example, the process 1200 may be implemented using the system 1300 of FIG. 13. Performing maintenance of individualmodular power converters in the series cascade while a modular power converter is being bypassed may serve to reduce down- time for a larger power conversion system. For example, the process 1200 may be implemented using the modular power converter 200 of FIG. 2. For example, the process 1200 may be implemented using the system 300 of FIG. 3. For example, the process 1200 may be implemented using the system 600 of FIG. 6.
[0104] FIG. 13 is a block diagram of an example of a system 1300 including a cascade of modular power converters used to supply power from an AC power source to a DC load with bypass circuitry that may be used to handle fault conditions and to perform maintenance on a bypassed modular power converter without imposing down-time on the DC load 104. The system 1300 has many of the same components described in relation to FIG. 1, with the addition of bypass circuitries, including the bypass circuitry 1330 and the bypass circuitry 1332. The system 1300 includes a first AC -to-DC converter 112 with AC terminals connected in series with multiple AC-to-DC converters (e.g., including a second AC -to-DC converter 122) between terminals of an AC power source 102; the bypass circuitry 1330 connected to the AC terminals, wherein the bypass circuitry 1330 is configured to be a short circuit of the AC terminals in a bypass mode and to be open circuit in a normal operating mode; a first energy storage device 114 connected to DC terminals of the first AC-to-DC converter 112; and a first DC-to-DC converter 116 with input terminals connected to the first energy storage device 114 and output terminals connected to a DC load 104. This cascaded arrangement of the modular power converters may be used to reduce the voltage stress of each converter's components and provide for lower harmonics, while using their DC outputs in parallel may provide high current loads and / or redundancy. Systems using this architecture for power conversion may achieve higher power density than conventional power converter architectures. For example, the system 1300 may be used to implement the process 700 of FIG. 7. For example, the system 1300 may be used to implement the process 800 of FIG. 8. For example, the system 1300 may be used to implement the process 1000 of FIG. 10. For example, the system 1300 may be used to implement the process 1100 of FIG. 11.
[0105] In some implementations, the bypass circuitry 1330 may include a mechanical switch. For example, the bypass circuitry 1330 may include the bypass circuitry 1400 of FIG. 14 A. In some implementations, the mechanical switch is external to a server tray containing the first AC- to-DC converter 112, the first energy storage device 114, and the first DC-to-DC converter 116 and the mechanical switch is configured to automatically transition the bypass circuitry 1330 tothe bypass mode when the server tray is removed from a server rack.
[0106] In some implementations, the bypass circuitry 1330 may include an electrical relay, an electrical contactor, or a solid-state switch (e.g., fast solid state relay (SSR) and an efficient relay). For example, the bypass circuitry 1330 may be mounted on the rack and may be activated when the modular power converter 110 fails, and it provides a current path to the next trays in the rack. In such a solution, the whole tray may be offline before its removal from the rack. For example, the bypass circuitry 1330 may include fault detection circuitry and may be configured to automatically transition to the bypass mode when a fault is detected in the first AC-to-DC converter 112, the first energy storage device 114, or the first DC-to-DC converter 116. For example, the bypass circuitryl330 may include the bypass circuitry 1450 of FIG. 14B.
[0107] The bypass circuitry 1330 may be external to a server tray that includes the modular power converter 110 in order to facilitate the removal of the server tray without disrupting operation of the system 1300. For example, the server tray may be removed as a step in a maintenance procedure for the modular power converter 110 or other equipment installed in the server tray. In some implementations, the bypass circuitry 1330 includes components external to a server tray containing the first AC-to-DC converter 112, the first energy storage device 114, and the first DC-to-DC converter 116.
[0108] The bypass circuitry 1332 may be similarly structured to the bypass circuitry 1330 and the bypass circuitry 1332 may play the same role with respect to the second modular power converter 120. In some implementations, each modular power converter in a series cascade of AC terminals of modular power converters has a respective bypass circuitry configured to function as the bypass circuitry 1330 functions with the modular power converter 110.
[0109] The operation of the modular power converters of the system 1300, including the first modular power converter 110 and the second modular power converter 120, arranged in a cascade may be configured and / or coordinated by a main or central controller (e.g., the main controller 614 of FIG. 6). This main controller may be implemented using a processing apparatus (e.g., the processing apparatus 900 of FIG. 9), which may be configured to transmit control signals to the first controller and respective controllers of the respective modular power converters that include the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter, to cause the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter 112 to coordinate to convert AC power from the AC power source 102 to energy stored in the first energy storage device 114 andrespective energy storage devices (e.g., including the energy storage device 124) of the respective modular power converters (e.g., including the modular power converter 120). In some implementations, the processing apparatus commands the first controller and respective controllers of the respective modular power converters to implement a phase shifted control solution for AC-to-DC power conversion. For example, the phase shifted control solution for AC-to-DC power conversion may operate as described in relation to FIG. 5. In some implementations, the processing apparatus commands the first controller and respective controllers of the respective modular power converters to implement a clamped, level-shifted control solution for AC-to-DC power conversion. For example, the clamped, level-shifted control solution for AC-to-DC power conversion may operate as described in relation to FIG. 4.
[0110] FIG. 14A is a schematic of an example of a bypass circuitry 1400 including a mechanical switch 1410. The bypass circuitry 1400 includes a mechanical switch 1410. The mechanical switch 1410 is connected to a first terminal 1420 of the bypass circuitry 1400 and to a second terminal 1422 of the bypass circuitry 1400. For example, the first terminal 1420 may be connected to a positive AC terminal of a modular power converter (e.g., the modular power converter 110) and the second terminal 1422 may be connected to a negative AC terminal of the modular power converter. In some implementations, the mechanical switch 1410 is external to a server tray containing the modular power converter and the mechanical switch 1410 is configured to automatically transition the bypass circuitry 1400 to the bypass mode when the server tray is removed from a server rack. For example, the mechanical switch 1410 may be connected to a latch that holds the server tray in a server rack, and the mechanical switch 1410 may be thrown when the latch is released to enable removal of the server tray that contains the modular power converter. In some implementations, the mechanical switch 1410 includes a backplane connector having spring-loaded contacts that bridge the gap between the first terminal 1420 and the second terminal 1422 when a server tray including the modular power converter is ejected. For example, the backplane connector may be a normally closed interconnect that only opens when pushed by the server tray.
[0111] FIG. 14B is a schematic of an example of a bypass circuitry 1450 including an electrical relay 1460 and a fault detection circuitry 1470 configured to control the relay 1460. In this example, the electrical relay 1460 includes an inductive coil 1462 and a single pole single throw (SPST) switch 1464 that is controlled by current in the inductive coil 1462. The bypass circuitry 1450 includes fault detection circuitry 1470 and is configured to automaticallytransition to a bypass mode when a fault is detected in a modular power converter (e.g., the modular power converter 110). For example, the fault detection circuitry 1470 may include current sensors and / or voltage sensors positioned near or integrated with the modular power converter to measure currents and / or voltages in the modular power converter. When a voltage or current in the modular power converter is detected to be outside of an expected range, the fault detection circuitry 1470 may drive a current, via conductor 1472, in the inductive coil 1462 to cause the SPST switch 1464 to transition to a closed state that short circuits a first terminal 1420 of the bypass circuitry 1450 to a second terminal 1482 of the bypass circuitry 1450. For example, the first terminal 1480 may be connected to a positive AC terminal of a modular power converter (e.g., the modular power converter 110) and the second terminal 1482 may be connected to a negative AC terminal of the modular power converter. In some implementations, the bypass circuitry 1450 includes components external to a server tray containing the modular converter.
[0112] Some implementations may provide one or more means for distributing and managing power associated with an operation of an electric power and / or supply application (e.g., a data center power system). For example, one or more systems and methods provide a means for utilizing charge pump gate drivers within a network of modular series-connected converters, which allows for capabilities for ultra-high and / or ultra-low duty cycles in multilevel converters. One or more herein described systems and methods provide a solution to conventional bootstrap gate drivers that may be used in power converters as they face limitations regarding duty cycle range. For example, one or more conventional implementations rely on self-driven mechanisms to charge bootstrap capacitors, which could affect the ability to function, and / or the reliability of functioning, at extreme duty cycles (e.g., near 0% or 100%). Such a limitation poses a challenge for modular multilevel converters, where operating some of the converters at ultra-low or ultra-high duty cycles is desirable. The use of a charge pump can support these cycles through supplying the bootstrap capacitor using an external circuit as described in more detail herein in connection with various examples.
[0113] For example, one or more systems and methods provide a means for one or more SIMs to communicate and / or make autonomous decisions associated with power management without use of a central or master controller. As such, challenges associated with the management of power across a network of dispersed SIMs due to inherent physical separation of energy storage devices may be reduced or eliminated. Such challenges could otherwise providelimitations to robust communication and collaborative decision-making between SIMs that allow for maintaining stability, balance, and / or protection. One or more examples may also provide a solution to a reliance upon a centralized architecture with a single master controller collecting data from all distributed components and making centralized decisions. As such, one or more herein described examples do not suffer from communication bottlenecks, single points of failure, and / or limited responsiveness. As network size and complexity increase, data volume may overwhelm central controllers, leading to delays and inefficiencies. If a central controller malfunctions, the malfunctions can compromise an entire system. Additionally, centralized decision-making can be slow and inflexible, which may hinder adaptation to rapid changes or unexpected events. One or more of such limitations may be mitigated by provision of a means for one or more SIMs to communication and / or make autonomous decisions without the need of a central or master controller, as described in more detail herein.
[0114] In some implementations, one or more systems and methods, described herein, provide a means for providing charging for an unlimited number of SIMs with one transformer. The systems and methods provide a solution to power supplying that may be created with a dual active bridge circuit in conventional data center power systems. For example, these circuits may be created by using an H-bridge connected to the primary of a transformer, while the secondary of the transformer is connected to another H-bridge. Since conventional systems may be connected directly to the high-voltage grid, high-voltage components may be used for this type of circuit. Some of these high-voltage components are not needed in a modular inverter as each SIM has a modular converter capable of providing current to or from the energy storage device. Such circuitry provides limitations to providing the power required for offering power supplying for an unlimited number of SIMs. Such limitations may be mitigated by providing power supplying for an unlimited number of SIMs with one transformer in accordance with one or more examples described herein.
[0115] In some implementations, one or more systems and methods provide a means for achieving simultaneous energy storage device balancing of the energy storage device during charging / discharging within individual SIMs, as described herein. The systems and methods may provide a solution to conventional systems that prefer to stop charging to rebalance the voltage or SOC among all energy storage devices, which could result in interruptions in charging, leading to wasted time. One or more implementations concurrently balance and charge / discharge within individual SIMs.
[0116] For example, one or more systems and methods may provide a means for providing multiple DC outputs using a DC-to-DC converter on each SIM. These systems and methods provide a solution to conventional data centers that often require multiple DC voltage levels. In traditional systems, a centralized DC-to-DC converter feeds the data center loads from the high- voltage grid. In modular multilevel systems, powering multiple DC voltages / loads while maintaining energy storage device independence between modules may present a challenge. One or more implementations utilize a DC-to-DC converter on each SIM. This configuration may enable the DC load to be supported by any or all of the energy storage device(s) of the SIMs.
[0117] Referring to FIG. 15, among other components, an electric power system 2100 is provided in a data center (not shown). The electric power system 2100 includes, among other components, a plurality of power control modules, configured in some examples as SIMs 2102a- 2102h. Each of the plurality of SIMs 2102a-2102h includes one or more energy storage devices 2104a-2104h (e.g., at least one battery module) electrically connected to at least one power supply unit 2106a-2106h. While the electric power system 2100 illustrated in FIG. 15 depicts a total of eight electrically connected SIMs 2102a-2102h, it is understood that the electric power system 2100 may include additional or fewer SIMs as is necessary or desired for any application.
[0118] The plurality of SIMs 2102a-2102h are electrically connected to at least one bus bar. As another example, a set of SIMs of the plurality of SIMs 2102a-2102h may be electrically connected to a bus bar 2108a having a first voltage, such as 12 volts (V), while another set of SIMs of the plurality of SIMs 2102a-2102h may be electrically connected to another bus bar 2108b having a second voltage different than the first voltage, such as 48V. It is understood that each of the set of SIMs of the plurality of SIMs 2102a-2102h and each of the bus bars 2108a,2108b are included within the electric power system 2100, and the bus bars can have different voltages. FIG. 15 also depicts that each of the two bus bars 2108a,2108b are connected to the data center load(s). The electric power system 2100 in various examples is configured to be implemented in single-phase, three-phase, and / or multi-phase application(s).
[0119] Each of the plurality of SIMs 2102a-2102h may include a direct current to alternating current (DC-to-AC) inverter, a DC-to-DC converter, an on-board DC and an on-board AC, a battery management system, and an electric controller. The AC-to-DC inverter is configured to accept AC power from the high voltage AC grid associated with the electric power system 2100 to at least one of the energy storage devices 2104a-2104h.
[0120] For example, the grid is a high-voltage grid that is connected to the data center. In one embodiment, the AC-to-DC inverter is provided as a three-level inverter having power electronics including power electronic switches, such as a metal - oxide - semiconductor fieldeffect transistor (MOSFET), an insulated-gate bipolar transistor (IGBT), a thyristor or a gate turn-off thyristor (GTO), among others. The power electronic switches are operable by a power controller (not shown) to generate a desired drive power output. In one form, the AC-to-DC inverter is provided as a bidirectional inverter, where output terminals connect to one another in series and parallel configurations to accept power from the grid. It should be readily understood that the AC-to-DC inverter may include additional and / or other components and should not be limited to what has been described herein. For example, the AC-to-DC inverter may include filters and / or components to isolate the DC- to-AC inverter from the DC-to-DC converter.
[0121] The DC-to-DC converter may be configured to generate DC power to a data center load from at least one of the energy storage devices 2104a-2104h of each of the plurality of SIMs 2102a-2102h. The DC-to-DC converter may be provided as an isolated converter having electronics such as, but not limited to, a flyback converter, half-bridge circuit, full-bridge circuit, and / or inductors and capacitor. In an embodiment, the DC-to-DC converter provides regulated DC output at 12V or 48V levels. However, the DC-to-DC converter can be configured in various suitable ways to individually or in association with other DC-to-DC converters provide auxiliary power output(s) to one or more of the power buses (e.g., bus bar 2108a, or bus bar 2108b), and should not be limited to the configuration illustrated in FIG 15.
[0122] In some implementations, the DC-to-DC converter is a bidirectional converter. It should be readily understood that the DC-to-DC converter may include additional and / or other components and should not be limited to what has been described herein. For example, the DC- to-DC converter may include filters, and / or may not include components to isolate the DC-to- DC converter from the DC-to-AC inverter.
[0123] Both of the DC charger and the AC charger are configured to charge the at least one of the energy storage devices 2104a-2104h of each of the plurality of SIMs 2102a-2102h from an electric grid or any other electrical power source(s). The energy storage management system may be configured to at least control, monitor, and / or protect the at least one of the energy storage devices 2104a-2104h of each of the plurality of SIMs 2102a-2102h. The electric controller(s) may be configured to digitally control each of the subsystems associated with the electric power system 2100 using local measurements. However, it is understood that the electriccontroller is configured to digitally control each of the subsystems associated with the electric power system 2100 using any measurements. It is also understood that the electric controller(s) may be configured to control each of the subsystems associated with the electric power system 2100 using manual means, hybrid digital / manual means, or any other means.
[0124] A charge pump gate driver 2200 is integrated within each of the plurality of SIMS 2102a-2102h. As an example, the charge pump gate driver 2200 is illustrated in FIG. 16. As a general example associated with a functionality of the charge pump gate driver 2200, the charge pump gate driver 2200 is a circuit that maintains voltage to the bootstrap capacitor(s). The voltage to the bootstrap capacitor may be maintained by charging a flying capacitor 2202 of the charge pump gate driver 2200 and discharging the flying capacitor 2202 of the charge pump gate driver 2200, for example. FIG. 16 illustrates a discharge flow 2204 and a charge flow 2206 associated with a distribution of power to the bootstrap capacitor. For example, in an instance where the charge flow 2206 and the discharge flow 2204 are activated, the charge pump gate driver 2200 can cause a first gate 2208 to close (e.g., turn OFF) and a fourth gate 2210 to close so that the discharge flow 2204 can be output across the flying capacitor 2202. The charge pump gate driver 2200 can simultaneously cause a third gate 2212 to open (e.g., turn ON) and a second gate 2214 to open so that the charge flow 2206 can be output across the flying capacitor 2202.
[0125] The charge pump gate driver 2200 provides each of the plurality of SIMs 2102a- 2102h with an ability to operate at extreme duty cycles (e.g., approximately 0% or approximately 100%). For example, in an instance wherein an AC voltage is within a range of a specific SIM of the plurality of SIMs 2102a-2102h internal source and / or internal load, the converter operates at a high frequency. As another example, the operation at the high frequency allows for the specific SIM of the plurality of SIMS 2102a-2102h to operate at a high level of frequency, which allows for the specific SIM of the plurality of SIMs 2102a-2102h to precisely control its power distribution.
[0126] Referring to FIG. 17, and as a further example to what has been discussed in the description related to FIG. 16, a first set of SIMs 2300a illustrates an allotment of power distribution associated with a first SIM 2302a of the first set of SIMs 2300a in the instance wherein the converter operates at a high frequency. A second SIM 2304a and any number of SIMs 2306a are placed in a charge mode while the power distribution may be controlled by the first SIM 2302a. Such an allotment of power distribution is depicted by a first graphical representation 2308 that shows a first reference signal 2310. The first reference signal 2310 isshown as a first sinusoidal waveform representing the positive and negative status (e.g., states, portions, or periods) of a duty cycle passing through the first SIM 2302a of the first set of SIMs 2300a. An upward trajectory of the first reference signal 2310 equates to the positive cycle. A crest 2312a of the first reference signal 2310 represents a duty cycle at 100% capacity. A downward trajectory of the first reference signal 2310 equates to the negative cycle. A trough 2314a of the first reference signal 2310 represents the duty cycle at 0% capacity. It is understood that the charge pump gate driver 2200 may handle any load associated with any range within the duty cycle represented in FIG. 17 (i.e., 0% - 100%).
[0127] For example, in an instance wherein an AC voltage is not within the range of the specific SIM of the plurality of SIMs 2102a-2102h internal energy storage device, the converter operates at either a 100% duty cycle or a 0% duty cycle. In some implementations, a second set of SIMs 2300b illustrates an allotment of power distribution associated with both a first SIM 2302b and a second SIM 2304b in the instance wherein the converter operates at either a 100% duty cycle or a 0% duty cycle. For example, as the AC voltage exceeds the range of the specific SIM of the plurality of SIMs 2102a-2102h internal energy storage device, the first SIM 2302b switches fully ON, providing approximately 100% duty cycle while the second SIM 2304b begins a high frequency operation. Any number of SIMs 2306b are placed in a charge mode while the power distribution is handled by both the first SIM 2302b and the second SIM 2304b.
[0128] Such an allotment of power distribution is depicted by a second graphical representation 2314 that shows a second reference signal 2316. The second reference signal 2316 is shown as a second sinusoidal waveform representing the positive and negative status of a duty cycle passing through the first SIM 2302b and the second SIMs 2304b of the second set of SIMs 2300b. An upward trajectory of the second reference signal 2316 equates to the positive cycle. A crest 2312b of the second reference signal 2316 represents a duty cycle at 100% capacity. A downward trajectory of the second reference signal 2316 equates to the negative cycle. A trough 2314b of the second reference signal 2316 represents the duty cycle at 0% capacity.
[0129] In some implementations, a decentralized approach to managing power loads associated with the plurality of SIMs 2102a-2102h and / or modular converters is thereby provided through the utilization of a shared communication pool. Through the utilization of the shared communication pool, each of the plurality of SIMs 2102a-2102h can communicate any type of data originating from each respective energy storage device to any component within theelectric power system 2100. It is understood that each of the plurality of SIMs 2102a-2102h can communicate any type of data originating from each of their respective energy storage device to any component even associated with the electric power system 2100 that may exist, for example, outside the electric power system 2100. The energy storage device(s) associated with each of the plurality of SIMs 2102a-2102h can be organized in ascending or descending order through the utilization of the shared communication pool. For example, the energy storage device(s) associated with each of the plurality of SIMs 2102a-2102h can be organized in ascending or descending order based on data originating from a particular SIM of the plurality of SIMs 2102a-2102h relative to other SIMs in the network (e.g., a comparison can be made between data originating from the particular SIM of the plurality of SIMs 2102a-2102h relative to the other SIMs in the network). In some implementations, a level of the energy storage device(s) can be a basis of the determination of the order in which each of the plurality of SIMs 2102a-2102h are placed. For example, the energy storage device(s) associated with each of the plurality of SIMs 2102a-2102h can be autonomously organized in ascending or descending order and / or communicate data without an external controller or master component. In some implementations, based on the energy storage device(s) associated with each of the plurality of SIMs 2102a-2102h that can be organized in ascending or descending order and / or communicate data, each of the plurality of SIMs 2102a-2102h can adjust their respective output / input so that their respective voltage(s) and / or state of charge(s) can be balanced through the load and / or charging to protect the energy storage devices of the other SIMs in the network. Fo example, the order that each of the plurality of SIMs 2102a-2102h are placed in can be indicative of a priority of which SIMs of the plurality of SIMs 2102a-2102h may require charging or any other support. For example, each of the plurality of SIMs 2102a-2102h can make decisions associated with the communication of data and / or the order by which they are placed in (e.g., based on their data in comparison to other SIMs on the network) based on local measurements such as temperature, current, voltage, or a combination thereof. It is understood that each of the plurality of SIMs 2102a-2102h can make decisions based on any metric and from any source, such as one or more remote measurements. For example, the decisions made by each of the plurality of SIMs 2102a- 2102h may be made by an internal controller integrated within each of the plurality of SIMs 2102a-2102h.
[0130] Within the embodiment relative to the decentralized approach to managing power loads associated with the plurality of SIMs 2102a-2102h, each of the plurality of SIMs 2102a-2102h retain operative characteristics associated with real-time data acquisition, network-aware decision-making, and autonomous execution. For example, each of the plurality of SIMs 2102a- 2102h can continuously collect and / or analyze local sensor data (e.g., temperature, current, voltage, or a combination thereof). For example, each of the plurality of SIMs 2102a-2102h can access and / or utilize data from the other SIMs in the network so that each of the SIMs 2102a- 2102h can have a comprehensive system state understanding. In some implementations, each of the plurality of SIMs 2102a-2102h can make independent decisions (e.g., control decisions) based on local data and / or network data including output adjustments, self-protection and inter- SIM protection, system performance optimization, or a combination thereof. For example, the output adjustments can involve any of the plurality of SIMs 2102a-2102h modifying its output to balance network supply and demand. As an additional example, the self-protection and inter- SIM protection can involve any of the plurality of SIMs 2102a-2102h implementing safety measures against overloads, under- voltages, etc., and protects the other SIMs in the network. In some implementations, the system performance optimization can involve any of the plurality of SIMs 2102a-2102h making real-time adjustments to maximize efficiency and / or minimizing energy losses.
[0131] Referring to FIG. 18, a charging topology 2400 utilizing at least one H-bridge on each of the plurality of SIMs 2102a-2102h connected to a secondary side 2402 of a transformer 2404 is illustrated. It is understood that each of the plurality of SIMs 2102a-2102h have modular series connected H-bridges disposed therein. The onboard charging topology 2400 generally includes a rectifier circuit 2406, an inverter circuit 2408, and the plurality of SIMs 2102a-2102h. The onboard charging topology 2400 may be configured to provide power through one or more low- voltage H-bridges disposed onboard each of the plurality of SIMs 2102a-2102h. The rectifier circuit 2406 may be configured to change the grid AC voltage to a DC voltage, which is ultimately connected to the inverter circuit 2408. The inverter circuit 2408 may be configured to change the power output from the DC voltage to a high frequency AC voltage (e.g., greater than 1 kHz). Causing the AC voltage to be changed to the DC voltage and then back to the AC voltage enables a smaller transformer to be used for power supplying. Furthermore, causing the AC voltage to be changed to the DC voltage and then back to the AC voltage enables the voltage on the secondary side of the transformer 2404 to supply power to each of the plurality of SIMs 2102a-2102h.
[0132] FIG. 19 shows an onboard charging topology 2500 that illustrates the enablement ofa targeted current flow that a module series-connected H-bridge provides each of the plurality of SIMs 2102a-2102h. For example, the targeted current flow can run through a specific SIM of the plurality of SIMs 2102a-2102h without affecting the input power and / or output power associated with the electric power system 2100.
[0133] Power (e.g., source and / or loads) originating at least from a second SIM 2502 and any number of SIMs 2504 is depicted as flowing toward a targeted module (e.g., a first SIM 2506) in FIG. 19. Such a targeted delivery of the power can balance a SOC across each of the plurality of SIMs 2102a-2102h. For example, in an instance wherein a controller determines that a particular SIM of the plurality of SIMs 2102a-2102h has a higher SOC compared to other energy storage devices associated with the other SIMs of the plurality of SIMs 2102a-2102h, the frequency that the particular SIM is placed in a current discharge path may increase. In some implementations, the particular SIM can be removed from a charging path in an instance where the electric power system 2100 is charging. By removing the particular SIM from the charging path, balance is created amongst the energy storage devices across the network. Such balance is created as the SIMs of the plurality of SIMs 2102a-2102h with lower SOC energy storage devices will charge more frequently, at least until the corresponding SOCs reach the levels of the SIMs of the plurality of SIMs 2102a-2102h that are higher.
[0134] In some implementations, the controller can determine a temperature associated with any of the SIMs of the plurality of SIMs 2102a-2102h. For example, in a case wherein a particular SIM is operating with a high-temperature (e.g., above a defined value), that particular SIM can be temporarily excluded from charging and or discharging associated with the plurality of SIMs 2102a-2102h. As another example, the controller can further determine that a particular SIM of the plurality of SIMs 2102a-2102h has malfunctioned and / or is faulty. As yet another example, in a case wherein the particular SIM has been identified as having malfunctioned and / or is faulty, the particular SIM can be isolated from the flow of power.
[0135] FIGS. 20 and 21 show an onboard charging topology 2600 that illustrates a simultaneous energy storage device balancing routine that occurs during charging, or discharging, associated with one or more SIMs of the plurality of SIMs 2102a-2102h. For example, the simultaneous energy storage device balancing routine that occurs during charging, or discharging, is provided within each of the plurality of SIMs 2102a-2102h. As is described above, current can be directed to, or from, a targeted energy storage device based on the modularity of the plurality of SIMs 2102a-2102h disposed within the electric power system2100. Such modularity of the plurality of SIMs 2102a-2102h provides for any of the SIMs of the plurality of SIMs 2102a-2102h to balance respective energy storage devices utilizing passive and / or active techniques while the unaffected SIMs disposed within the electric power system 2100 continues to charge.
[0136] In an instance wherein the energy storage device balancing routine is implemented, any affected SIMs of the plurality of SIMs 2102a-2102h utilize respective open-circuit voltages to eliminate any influence associated with the charging current and / or to facilitate precise adjustments to the affected SIM(s) of the plurality of SIMs 2102a-2102h. As an example, in the instance wherein the energy storage device balancing routine is implemented, specific SIMs of the plurality of SIMs 2102a-2102h can receive a dedicated charging current while other SIMs of the plurality of SIMs 2102a-2102h simultaneously undergo balancing. However, it is understood that the other SIMs of the plurality of SIMs 2102a-2102h can undergo balancing at any time. It is also understood that this decoupling-related operation allows for uninterrupted charging across the electric power system 2100.
[0137] FIG. 20 specifically depicts an instance wherein the first SIM 2506 is balanced, and thus has power flowing (e.g., a charging loop) through the first SIM 2506. While power runs through the first SIM 2506, both the second SIM 2502 and the any number of SIMs 2504 are left out of the charging loop so that the elements of the energy storage device (e.g., battery cells) can be balanced. FIG. 21 specifically depicts an instance wherein the second SIM 2502 is rebalanced, and thus re-enters the charging queue while the first SIM 2506 begins the energy storage device balancing routine. As an example, the electric power system 2100 is further able to balance any of the plurality of SIMs 2102a-2102h during discharging of the cells. For example, if an AC load does not require all of the SIMs of the plurality of SIMs 2102a-2102h at any given point, the electric power system 2100 will cause at least some of the SIMs of the plurality of SIMs 2102a-2102h to be removed from the power flow path so that the electric power system 2100 may balance itself.
[0138] FIGS. 22 and 23 illustrate a topography 2700 related to scalable power balancing associated with the implementation of bidirectional DC-to-DC converters within the electric power system 2100. For example, at least one bidirectional DC-to-DC converter of the bidirectional DC-to-DC converters is integrated within each of the SIMs of the plurality of SIMs 2102a-2102h. In some implementations, the DC load side 2702 of the bidirectional DC-to-DC converters may be connected in a parallel / series network while the other side 2704 is connectedto the SIM’s energy storage device.
[0139] In some examples, connecting the DC load sides 2702 in parallel enables powersharing between each of the plurality of SIMs 2102a-2102h. For example, by connecting the DC load sides 2702 in parallel, power from a SIM with a higher voltage and / or a higher SOC is able to be transferred to SIMs with a lower voltage and / or a lower SOC. In some implementations, a SIM may transfer power to another SIM’s energy storage device via a parallel connection between at least two bi-directional DC-to-DC converters (e.g., respective to the SIM and another SIM) to provide a balancing routine to level a low voltage and / or a low SOC. For example, by connecting the DC load sides 2702 in parallel, individual SIMs of the plurality of SIMs 2102a- 2102h are able to isolate their energy storage devices contributions to an overall DC load 2706.
[0140] Referring particularly to FIG. 23, an alternative balancing routine utilizing at least one DC-to-DC converter in combination with dedicated discharge paths in a DC-to-DC converter model 2800 is depicted therein. For example, one or more DC-to- DC converters equipped to dynamically control DC output ports through remote control and / or local control are integrated within each of the plurality of SIMs 2102a-2102h. For example, the electrical sources and / or electrical loads can be balanced through the DC load based on the DC-to-DC converter model 2800. In some implementations, energy storage devices with higher voltage and / or SOC can provide more power to the DC load 2706 while energy storage devices with lower voltage and / or SOC can contribute less power to the DC load 2706. It is understood, however, that the energy storage devices with lower voltage and / or SOC can contribute no power at all to the DC load 2706. For example, through usage and / or time, the electrical sources and / or electrical loads associated with each of the plurality of SIMs 2102a-2102h will discharge down to a level where each of the plurality of SIMs 2102a-2102h are balanced.
[0141] FIG. 24 illustrates a graphical representation 2900 of the function of the topography 2700 related to scalable power balancing associated with the implementation of the DC-to-DC converters within the electric power system 2100. The graphical representation depicts an instance where a method of control of each of the plurality of SIMs 2102a-2102h are adjusted so that the efficiency associated with the electric power system 2100 is maintained at a maximum.
[0142] For example, the same DC load is supplied to the DC-to-DC converter of each of the plurality of SIMs 2102a-2102h. The controller is configured to determine which SIM(s) of the plurality of SIMs 2102a-2102h would provide an output through the DC-to-DC converter and / or how much contribution each of the plurality of SIMs 2102a-2102h would be required to achievemaximum system efficiency.
[0143] For example, the curve representing an input 2902 at 12 Volts can achieve maximum efficiency at 2904 (at approximately 6 Amps), which amounts to approximately 72 Watts. As another example, in a case wherein a load is 150 Watts, and four SIMs are connected in the network, based on the curves shown in FIG. 23, for the electric power system 2100 to operate at maximum efficiency would likely require use of two SIMs at approximately 75 watts each while turning the two SIMs with the lowest SOC off. By optimizing the network with four SIMs in this way, the efficiency of the electric power system 2100 would be approximately 88% at 2906. In some implementations, if all three SIMs evenly shared the load, then each of the three SIMs would provide approximately 50 watts, which would cause the efficiency of the electric power system 2100 to be approximately 86%.
[0144] FIG. 25 depicts circuitry 21000 illustrating the provision of at least two or more AC loads (e.g., a first AC load 21002 and a second AC load 21004) via the utilization of one or more strings of series-connected power converters. FIG. 25 specifically depicts an example configuration of the circuitry 21000 wherein each string of the series-connected power converters can individually control any AC load separately or in parallel with any other string of the series-connected power converters. For example, because each of the AC loads are wired to each of the series-connected power converters, power can be supplied to an unlimited number of AC loads enabling the balancing of any number of energy storage devices across strings. In some implementations, if an AC load draws more power than another AC load, the respective string of the series-connected power converters with a higher voltage and / or SOC can be used enabling a balancing routine that can be implemented across various strings of the series- connected power converters supplying different AC loads.
[0145] FIG. 26 depicts an alternative circuitry 21100 in comparison to FIG. 25 wherein each string of the series-connected power converters can power a single AC load or be placed in parallel to supply different AC loads at the same time by reducing the number of switches used.
[0146] FIG. 27 illustrates an example configuration 21200 of energy storage devices within a single SIM of the plurality of SIMs 2102a-2102h. For example, the placement of multiple energy storage devices within the single SIM of the plurality of SIMs 2102a-2102h allows each SIM of the plurality of SIMs to produce multiple voltage outputs while splitting a current required from energy storage devices at lower voltages. As an example, in order for energy storage devices BT1 21202 and BT2 21204 or BT3 21206 and BT4 21208 to be placed within aparallel configuration, electrical switching elements QI 21210 and Q3 21212 are on. As another example, in order for the energy storage devices BT1 21202 and BT2 21204 or BT3 21206 and BT4 21208 to be placed within a series configuration, Q2 21214 is on.
[0147] FIG. 28 illustrates an example of circuitry 21300 that provides a plurality of DC outputs on each of the plurality of SIMs 2102a-2102h by using a DC-to-DC converter so that the DC load can be supported by any of the plurality of SIMs 2102a-2102h energy storage device. For example, each of the plurality of SIMs 2102a-2102h have a respective DC-to-DC converter integrated therein. For example, any of the plurality of DC outputs can produce different voltage levels to support different DC networks. In some implementations, the plurality of DC outputs are connected within each of the plurality of SIMs 2102a-2102h in either a parallel configuration, a series configuration, or a parallel / series configuration. For example, the plurality of DC outputs are connected within each of the plurality of SIMs 2102a-2102h in either a parallel configuration, a series configuration, or a parallel / series configuration based on a required voltage and / or current of the DC load.
[0148] In an example embodiment, a multi-winding transformer generates both DC output 1 21302 and DC output 2 21304. As is depicted in FIG. 27, DC output 1 21302 is connected in parallel to support a low voltage DC load 21306 while DC output 2 21304 is connected in series to support a high voltage DC load 21308.
[0149] FIG. 29 illustrates a modular electric powertrain system 21400 that provides for AC charging utilizing isolation on each of the plurality of SIMs 2102a-2102h in a modular multilevel system. For example, in such a modular multilevel system, the energy storage devices are separated from each of the plurality of SIMs 2102a-2102h so that a single transformer may be utilized on each of the plurality of SIMs 2102a-2102h.
[0150] For example, an AC input can be connected or disconnected to the same power source providing the high-voltage DC load. In some implementations, the AC input frequency of each of the plurality of SIMs 2102a-2102h can be increased and passed to each transformer of each of the plurality of SIMs 2102a-2102h simultaneously or separately. For example, the AC input frequency of each of the plurality of SIMs 2102a-2102h can be increased and passed to each transformer of each of the plurality of SIMs 2102a-2102h based on each of the plurality of SIMs 2102a-2102h having respective switching circuitry integrated therein. In some implementations, the AC can be turned back or converted back to the appropriate DC through the utilization of the H-bridge connected to each of the plurality of SIMs 2102a-2102h energystorage devices.
[0151] FIG. 30 illustrates an example embodiment wherein the plurality of SIMs 2102a- 2102h are implemented within a data center rack 21500a to optimize a distribution of current across one or more data center loads 21502a-21502j within an industry compliant model (e.g., within safety standards of the industry). In one or more examples, the data center rack 21500a generally includes the one or more data center loads 21502a-21502j, one or more energy storage units 21504a-21504g, and the plurality of SIMs 2102a-2102g.
[0152] In some implementations, and with particular regard to the illustration provided in FIG. 30, the one or more energy storage units 21504a-21504f is assembled in a series formation individually coupled to each SIM of the plurality of SIMs 2102a-2102g. Each SIM of the plurality of SIMs 2102a-2102g is also assembled in a series formation similar to the assembly of the one or more energy storage units 21504a-21504f. While each SIM of the plurality of SIMs 2102a-2102g is disposed atop of a respective energy storage unit of the one or more energy storage units 21504a-21504f, it is understood that each SIM of the plurality of SIMs 2102a- 2102g may be disposed anywhere in relation to its respective energy storage unit of the one or more energy storage units 21504a-21504f as long as each SIM of the plurality of SIMs 2102a- 2102g is electrically coupled to its respective energy storage unit of the one or more energy storage units 21504a-21504f.
[0153] In some implementations, 480V is applied to the data center rack 21500a. It is understood that while a single phase (e.g., phase A) is illustrated as being applied to the data center rack 21500a, additional phases (e.g., phase B and phase C) can be applied to additional data center racks 21500b and 21500c, respectively. In one or more examples, the assembly of the plurality of SIMs 2102a-2102g in the series formation effectuates even distribution of the voltage applied to the data center rack 21500a, which is 80V in the illustrated example of FIG. 30. However, it is understood that any voltage may be applied to the data center rack 21500a and that any amount of voltage may be distributed across the plurality of SIMs 2102a-2102g.
[0154] Each SIM of the plurality of SIMs 2102a-2102g is configured to feed its respective energy storage unit of the one or more energy storage units 21504a-21504f. In turn, and in one or more embodiments, each energy storage unit of the one or more energy storage units 21504a- 21504f may be configured to be electrically coupled to (e.g., in support of) an adjacent data center load of the one or more data center loads 21502a-21502j. As an example, the energy storage unit 21504a may be configured to be electrically coupled to the data center load 21502a.In one or more embodiments, a singular energy storage unit of the one or more energy storage units 21504a-21504f may be configured to be electrically coupled to (e.g., in support of) more than a single data center load of the one or more data center loads 21502a-21502j. For example, the energy storage unit 21504c is configured to be electrically coupled to both the data center load 21502c and the data center load 21502e. It is understood that the connections between the energy storage units 21504a-21504f and the one or more data center loads 21502a-21502j may be based on one or more load requirements of a particular use-case and / or system in various implementations.
[0155] Throughout use of the data center rack 21500a, a charge associated with each energy storage unit of the one or more energy storage units 21504a-21504f may be maintained at a certain state of charge as a security measure to accommodate a scenario wherein the electric source shuts off to ensure that each energy storage unit of the one or more energy storage units 21504a-21504f is still able to properly manage the electric load.
[0156] In one or more examples, each data center load of the one or more data center loads 21502a-21502j is paired to a printed circuit board (not shown) that includes a graphics processing unit (not shown). Each data center load of the one or more data center loads 21502a- 21502j also includes an isolated DC-to-DC converter (not shown) that is configured to accept the distributed electrical load and to reduce the electrical load to an amount acceptable to a load capacity associated with the printed circuit board. The isolated DC-to-DC converter can also be a point of common coupling between each energy storage unit of the energy storage units 21504a-21504f.
[0157] FIG. 31 illustrates a voltage doubler circuit 21600 that can be used to support the modular AC -to-DC power conversion as described herein. In some implementations, the voltage doubler circuit 21600 can be included within each energy storage unit of the one or more energy storage units 21504a-21504f that is configured to boost a voltage level without requiring additional batteries to be included within the data center rack 21500a. For example, a first capacitor 21602a and a second capacitor 21602b may be continuously charged based on power received from an H-bridge terminal. In some implementations, in a case where a first switch 21604a is closed, the first capacitor 21602a is placed in parallel with a battery 21606 and the first capacitor 21602a discharges itself until its voltage equals a voltage of the battery 21606. For example, in an instance wherein the second switch 21604b is closed, the second capacitor 21602b discharges itself to match the voltage of the battery 21606. It is understood that byalternating the switching between the first switch 21604a and the second switch 21604b, a voltage at the H-bridge terminal may effectively become twice the voltage of the battery 21606.
[0158] In a first aspect, the subject matter described in this specification can be embodied in a system that includes a first AC-to-DC converter with AC terminals connected in series with multiple AC-to-DC converters between terminals of an AC power source; a first energy storage device connected to DC terminals of the first AC-to-DC converter; and a first DC-to-DC converter with input terminals connected to the first energy storage device, wherein output terminals of the first DC-to-DC converter are connected in parallel with multiple DC-to-DC converters between terminals of a DC load. In the first aspect, the first DC-to-DC converter may include an isolation component. In the first aspect, the isolation component of the first DC-to- DC converter may include a transformer. In the first aspect, the first AC-to-DC converter may include an isolation component. In the first aspect, the first AC-to-DC converter may include four switches connected in an H-bridge topology. For example, the four switches may be MOSFETs. In the first aspect, the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter may be components of a first modular power converter contained within a housing that exposes the AC terminals of the first AC-to-DC converter and the output terminals of the first DC-to-DC converter. In the first aspect, the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter may be components of a first modular power converter that are mounted on a circuit board along with a first controller of the first modular power converter that is configured to control switching in the first AC-to-DC converter and in the first DC-to-DC converter. In the first aspect, the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter may also be components of respective modular power converters with components that match the components of the first modular power converter. In the first aspect, the AC power source may be one phase leg of a multi-phase AC power line, and AC power on another phase leg of the multi-phase AC power line may also be converted using a series cascade of modular power converters with components that match the components of the first modular power converter. In the first aspect, output terminals of respective DC-to-DC converters in the series cascade of modular power converters may be connected in parallel with the output terminals of the first DC-to-DC converter. In the first aspect, the system may include a processing apparatus configured to transmit control signals to the first controller and respective controllers of the respective modular power converters that include the multiple AC-to-DC converters connectedin series with the AC terminals of the first AC-to-DC converter, to cause the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter to coordinate to convert AC power from the AC power source to energy stored in the first energy storage device and respective energy storage devices of the respective modular power converters. In the first aspect, the processing apparatus may command the first controller and respective controllers of the respective modular power converters to implement a phase shifted control solution for AC-to-DC power conversion. In the first aspect, the processing apparatus may command the first controller and respective controllers of the respective modular power converters to implement a clamped, level-shifted control solution for AC-to-DC power conversion. In the first aspect, the first energy storage device may be a capacitor. In the first aspect, the first energy storage device may be a battery. In the first aspect, the DC load may include a server installed in a server rack.
[0159] In a second aspect, the subject matter described in this specification can be embodied in methods that include converting AC power to DC power using a series cascade of modular power converters; and supplying DC power to a DC load using DC outputs of the modular power converters connected in parallel. In the second aspect, the methods may include providing isolation to the DC load using respective transformers of the modular power converters. In the second aspect, the methods may include storing back-up power for the DC load in respective capacitors of the modular power converters. In the second aspect, the methods may include storing back-up power for the DC load in respective batteries of the modular power converters. In the second aspect, converting AC power to DC power using the series cascade of modular power converters may include implementing a phase shifted control solution for AC-to-DC power conversion. In the second aspect, converting AC power to DC power using the series cascade of modular power converters may include implementing a clamped, level-shifted control solution for AC-to-DC power conversion. In the second aspect, the DC load may include a server installed in a server rack.
[0160] In a third aspect, the subject matter described in this specification can be embodied in system that includes a modular power converter comprising: a means for converting AC power to DC power with AC terminals connected in series with multiple AC-to-DC converters between terminals of an AC power source; a capacitor connected to DC terminals of the means for converting AC power to DC power; and a means for converting DC power to DC power with magnetic isolation with input terminals connected to the capacitor, and output terminalsconnected in parallel with multiple DC-to-DC converters between terminals of a DC load. In the third aspect, the DC load may include a server installed in a server rack.
[0161] In a fourth aspect, the subject matter described in this specification can be embodied in a system that includes a first AC-to-DC converter with AC terminals connected in series with multiple AC-to-DC converters between terminals of an AC power source; a bypass circuitry connected to the AC terminals, wherein the bypass circuitry is configured to be a short circuit of the AC terminals in a bypass mode and to be open circuit in a normal operating mode; a first energy storage device connected to DC terminals of the first AC-to-DC converter; a first DC-to- DC converter including input terminals connected to the first energy storage device and output terminals connected in parallel with multiple DC-to-DC converters between terminals of a DC load; and a transformer configured to provide isolation between the AC power source and the DC load. In the fourth aspect, the transformer may be part of the first DC-to-DC converter. In the fourth aspect, the transformer may be part of the first AC-to-DC converter. In the fourth aspect, the bypass circuitry may include a mechanical switch. In the fourth aspect, the mechanical switch may be external to a server tray containing the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter and the mechanical switch may be configured to automatically transition the bypass circuitry to the bypass mode when the server tray is removed from a server rack. In the fourth aspect, the bypass circuitry may include an electrical relay, an electrical contactor, or a solid-state switch. In the fourth aspect, the bypass circuitry may include fault detection circuitry and may be configured to automatically transition to the bypass mode when a fault is detected in the first AC-to-DC converter, the first energy storage device, or the first DC-to-DC converter. In the fourth aspect, the bypass circuitry may include components external to a server tray containing the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter. In the fourth aspect, the first AC-to-DC converter may include four switches connected in an H-bridge topology. In the fourth aspect, the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter may be components of a first modular power converter contained within a housing that exposes the AC terminals of the first AC-to-DC converter and the output terminals of the first DC-to-DC converter. In the fourth aspect, the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter may be components of a first modular power converter that are mounted on a circuit board along with a first controller of the first modular power converter that is configured to control switching in the first AC-to-DC converter and in the first DC-to-DCconverter. In the fourth aspect, the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter may also be components of respective modular power converters with components that match the components of the first modular power converter. In the fourth aspect, the AC power source may be one phase leg of a multi-phase AC power line, and AC power on another phase leg of the multi-phase AC power line may also be converted using a series cascade of modular power converters with components that match the components of the first modular power converter, and output terminals of respective DC-to-DC converters in the series cascade of modular power converters may be connected in parallel with the output terminals of the first DC-to-DC converter. In the fourth aspect, the system may include a processing apparatus configured to: transmit control signals to the first controller and respective controllers of the respective modular power converters that include the multiple AC- to-DC converters connected in series with the AC terminals of the first AC-to-DC converter, to cause the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter to coordinate to convert AC power from the AC power source to energy stored in the first energy storage device and respective energy storage devices of the respective modular power converters. In the fourth aspect, the processing apparatus may command the first controller and respective controllers of the respective modular power converters to implement a phase shifted control solution for AC-to-DC power conversion. In the fourth aspect, the processing apparatus may command the first controller and respective controllers of the respective modular power converters to implement a clamped, level-shifted control solution for AC-to-DC power conversion. In the fourth aspect, the first energy storage device may be a capacitor. In the fourth aspect, the first energy storage device may be a battery. In the fourth aspect, the DC load may include a server installed in a server rack.
[0162] In a fifth aspect, the subject matter described in this specification can be embodied in methods that include converting AC power to DC power using a series cascade of modular power converters; supplying DC power to a DC load using DC outputs of the modular power converters connected in parallel; bypassing one of the modular power converters in the series cascade of modular power converters by shorting AC terminals of the bypassed modular power converter; and continuing to supply DC power to the DC load using DC outputs of the modular power converters, excepting the bypassed modular power converter. In the fifth aspect, the methods may include detecting a fault condition in one of the modular power converters, wherein the bypassed modular power converter is bypassed responsive to detection of the faultcondition. In the fifth aspect, the methods may include performing maintenance on the bypassed modular power converter after bypassing the bypassed modular power converter. In the fifth aspect, the bypassed modular power converter may be bypassed using a mechanical switch. In the fifth aspect, the mechanical switch may be external to a server tray containing the bypassed modular power converter and the mechanical switch may be configured to automatically bypass the bypassed modular power converter when the server tray is removed from a server rack. In the fifth aspect, the bypassed modular power converter may be bypassed using an electrical relay, an electrical contactor, or a solid-state switch. In the fifth aspect, the methods may include providing isolation to the DC load using respective transformers of the modular power converters. In the fifth aspect, the methods may include storing back-up power for the DC load in respective capacitors of the modular power converters. In the fifth aspect, the methods may include storing back-up power for the DC load in respective batteries of the modular power converters. In the fifth aspect, converting AC power to DC power using the series cascade of modular power converters may include implementing a phase shifted control solution for AC-to- DC power conversion. In the fifth aspect, converting AC power to DC power using the series cascade of modular power converters may include implementing a clamped, level-shifted control solution for AC-to-DC power conversion. In the fifth aspect, the DC load may include a server installed in a server rack.
[0163] In a sixth aspect, the subject matter described in this specification can be embodied in a system that includes a first AC-to-DC converter with AC terminals connected in series with multiple AC-to-DC converters between terminals of an AC power source; a bypass circuitry connected to the AC terminals, wherein the bypass circuitry is configured to be a short circuit of the AC terminals in a bypass mode and to be open circuit in a normal operating mode; a first energy storage device connected to DC terminals of the first AC-to-DC converter; and a first DC-to-DC converter with input terminals connected to the first energy storage device and output terminals connected to a DC load. In the sixth aspect, the bypass circuitry may include a mechanical switch. In the sixth aspect, the mechanical switch may be external to a server tray containing the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter and the mechanical switch may be configured to automatically transition the bypass circuitry to the bypass mode when the server tray is removed from a server rack. In the sixth aspect, the bypass circuitry may include an electrical relay, an electrical contactor, or a solid- state switch. In the sixth aspect, the bypass circuitry may include fault detection circuitry andmay be configured to automatically transition to the bypass mode when a fault is detected in the first AC -to-DC converter, the first energy storage device, or the first DC-to-DC converter. In the sixth aspect, the bypass circuitry may include components external to a server tray containing the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter. In the sixth aspect, the output terminals of the first DC-to-DC converter may be connected in parallel with multiple DC-to-DC converters between terminals of the DC load. In the sixth aspect, the first DC-to-DC converter may include an isolation component. In the sixth aspect, the isolation component of the first DC-to-DC converter may include a transformer. In the sixth aspect, the first AC-to-DC converter may include an isolation component. In the sixth aspect, the first AC-to-DC converter may include four switches connected in an H-bridge topology. In the sixth aspect, the four switches may be MOSFETs. In the sixth aspect, the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter may be components of a first modular power converter contained within a housing that exposes the AC terminals of the first AC-to-DC converter and the output terminals of the first DC-to-DC converter. In the sixth aspect, the first AC-to-DC converter, the first energy storage device, and the first DC-to- DC converter may be components of a first modular power converter that are mounted on a circuit board along with a first controller of the first modular power converter that is configured to control switching in the first AC-to-DC converter and in the first DC-to-DC converter. In the sixth aspect, the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter may also be components of respective modular power converters with components that match the components of the first modular power converter. In the sixth aspect, the AC power source may be one phase leg of a multi-phase AC power line, and AC power on another phase leg of the multi-phase AC power line may also be converted using a series cascade of modular power converters with components that match the components of the first modular power converter, and output terminals of respective DC-to-DC converters in the series cascade of modular power converters may be connected in parallel with the output terminals of the first DC-to-DC converter. In the sixth aspect, the system may include a processing apparatus configured to: transmit control signals to the first controller and respective controllers of the respective modular power converters that include the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter, to cause the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter to coordinate to convert AC power from the AC power source to energy stored in the first energystorage device and respective energy storage devices of the respective modular power converters. In the sixth aspect, the processing apparatus may command the first controller and respective controllers of the respective modular power converters to implement a phase shifted control solution for AC-to-DC power conversion. In the sixth aspect, the processing apparatus may command the first controller and respective controllers of the respective modular power converters to implement a clamped, level-shifted control solution for AC-to-DC power conversion. In the sixth aspect, the first energy storage device may be a capacitor. In the sixth aspect, the first energy storage device may be a battery. In the sixth aspect, the DC load may include a server installed in a server rack.
[0164] In a seventh aspect, the subject matter described in this specification can be embodied in a system that includes a means for converting AC power to DC power with AC terminals connected in series with multiple AC-to-DC converters between terminals of an AC power source; a means for bypassing the means for converting AC power to DC power by shorting the AC terminals of the means for converting AC power to DC power; a capacitor connected to DC terminals of the means for converting AC power to DC power; and a means for converting DC power to DC power with magnetic isolation with input terminals connected to the capacitor, and output terminals connected in parallel with multiple DC-to-DC converters between terminals of a DC load. In the seventh aspect, the DC load may include a server installed in a server rack.
[0165] In an eighth aspect, the subject matter described in this specification can be embodied in a system that includes a housing that comprises a plurality of energy storage units, a plurality of data center loads, and a plurality of electrically connected power supply units, wherein: the plurality of electrically connected power supply units is configured as a plurality of smart integrated modules (SIMs) that are electrically connected to each other, and wherein each SIM of the plurality of SIMs is electrically connected to each energy storage unit of the plurality of energy storage units; and each energy storage unit of the plurality of energy storage units is configured to distribute electrical power to each data center load of the plurality of data center loads. In the eighth aspect, each SIM of the plurality of SIMs may include at least one of a bidirectional or uni-directional DC-to-AC power converter, a bi-directional or a uni-directional DC-to-DC power converter, a battery management module, and a local controller. In the eighth aspect, each SIM of the plurality of SIMs may comprise one or more gate drivers configured to switch the bi-directional or the uni-directional DC-to-AC power converter on and off, and theone or more gate drivers may be configured as an isolated gate driver, a bootstrap gate driver, or a charge pump gate driver. In the eighth aspect, each SIM of the plurality of SIMs may be adjacently disposed in relation to each energy storage unit of the plurality of energy storage units. In the eighth aspect, each SIM of the plurality of SIMs may be further configured to have a separate DC output that is connected to a separate data center load of the plurality of data center loads. In the eighth aspect, each SIM of a first plurality of SIMs may be further configured to connect a DC output bus associated with each SIM of the first plurality of SIMs in parallel or in series with a DC output bus associated with each SIM of a second plurality of SIMs. In the eighth aspect, each data center load of the plurality of data center loads may be electrically connected to the DC output bus associated with each SIM of the first plurality of SIMs or the DC output bus associated with each SIM of the second plurality of SIMs at an output of each SIM of the plurality of SIMs. In the eighth aspect, each data center load of the plurality of data center loads is configured to: accept the electrical power at an isolated DC-to- DC converter; and reduce a voltage level to a predefined level to provide the reduced voltage level to a printed circuit board, wherein each data center load of the plurality of data center loads includes the printed circuit board. In the eighth aspect, each SIM of the plurality of the SIMs may have a regulating DC-to-DC converter connected between each energy storage unit of the plurality of energy storage units and each data center load of the plurality of data center loads. In the eighth aspect, the system may include a voltage doubler circuit, wherein the voltage doubler circuit is configured to increase a voltage level at an AC power side associated with each SIM of the plurality of SIMs. In the eighth aspect, the system may include one or more uninterrupted power supply units configured to use a same energy storage unit from the plurality of energy storage units in a power conversion process from a grid associated with each data center load of the plurality of data center loads. In the eighth aspect, each SIM of the plurality of SIMs may be further configured to control one or more local variables, in an associated battery energy storage and in the SIM while performing one or more power conversions, and the one or more local variables may include a state of charge, a temperature, a state of health, or a combination thereof. In the eighth aspect, each SIM of the plurality of SIMs may be further configured to balance a state of charge of one or more associated modules based on a switching sequence in relation to the plurality of the SIMs. In the eighth aspect, wherein each SIM of the plurality of the SIMs may be configured to communicate with the plurality of the SIMs or a central controller to determine a switching sequence. In the eighth aspect, each SIM of the plurality ofthe SIMs may be configured to balance a state of charge of one or more cells of each SIM of the plurality of SIMs while performing one or more system functionalities.
[0166] As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C. ”
[0167] While the disclosure has been described in connection with certain embodiments, it is to be understood that the disclosure is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures.
Claims
What is claimed is:
1. A system for modular power conversion with high power density comprising: a first AC-to-DC converter with AC terminals connected in series with multiple AC-to- DC converters between terminals of an AC power source; a bypass circuitry connected to the AC terminals, wherein the bypass circuitry is configured to be a short circuit of the AC terminals in a bypass mode and to be open circuit in a normal operating mode; a first energy storage device connected to DC terminals of the first AC-to-DC converter; a first DC-to-DC converter including input terminals connected to the first energy storage device and output terminals connected in parallel with multiple DC-to-DC converters between terminals of a DC load; and a transformer configured to provide isolation between the AC power source and the DC load.
2. The system of claim 1, in which the bypass circuitry includes a mechanical switch.
3. The system of claim 2, in which the mechanical switch is external to a server tray containing the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter and the mechanical switch is configured to automatically transition the bypass circuitry to the bypass mode when the server tray is removed from a server rack.
4. The system of claim 1, in which the bypass circuitry includes an electrical relay, an electrical contactor, or a solid-state switch.
5. The system of claim 4, in which the bypass circuitry includes fault detection circuitry and is configured to automatically transition to the bypass mode when a fault is detected in the first AC-to-DC converter, the first energy storage device, or the first DC-to-DC converter.
6. The system of claim 1, in which the bypass circuitry includes components external to a server tray containing the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter.
7. The system of claim 1, in which the first AC-to-DC converter includes four switches connected in an H-bridge topology.
8. The system of claim 1, in which the first AC -to-DC converter, the first energy storage device, and the first DC-to-DC converter are components of a first modular power converter contained within a housing that exposes the AC terminals of the first AC-to-DC converter and the output terminals of the first DC-to-DC converter.
9. The system of claim 1, in which the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter are components of a first modular power converter that are mounted on a circuit board along with a first controller of the first modular power converter that is configured to control switching in the first AC-to-DC converter and in the first DC-to-DC converter.
10. The system of claim 9, in which the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter are also components of respective modular power converters with components that match the components of the first modular power converter.
11. The system of claim 10, in which the AC power source is one phase leg of a multi-phase AC power line, and AC power on another phase leg of the multi-phase AC power line is also converted using a series cascade of modular power converters with components that match the components of the first modular power converter, wherein output terminals of respective DC-to- DC converters in the series cascade of modular power converters are connected in parallel with the output terminals of the first DC-to-DC converter.
12. The system of claim 10, comprising a processing apparatus configured to: transmit control signals to the first controller and respective controllers of the respective modular power converters that include the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter, to cause the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter to coordinate to convert AC power from the AC power source to energy stored in the first energystorage device and respective energy storage devices of the respective modular power converters.
13. The system of claim 12, in which the processing apparatus commands the first controller and respective controllers of the respective modular power converters to implement a phase shifted control solution for AC-to-DC power conversion.
14. The system of claim 12, in which the processing apparatus commands the first controller and respective controllers of the respective modular power converters to implement a clamped, level-shifted control solution for AC-to-DC power conversion.
15. The system of claim 1, in which the first energy storage device is a capacitor.
16. The system of claim 1, in which the first energy storage device is a battery.
17. The system of claim 1, in which the DC load includes a server installed in a server rack.
18. A method comprising: converting AC power to DC power using a series cascade of modular power converters; supplying DC power to a DC load using DC outputs of the modular power converters connected in parallel; bypassing one of the modular power converters in the series cascade of modular power converters by shorting AC terminals of the bypassed modular power converter; and continuing to supply DC power to the DC load using DC outputs of the modular power converters, excepting the bypassed modular power converter.
19. The method of claim 18, comprising: detecting a fault condition in one of the modular power converters, wherein the bypassed modular power converter is bypassed responsive to detection of the fault condition.
20. The method of claim 18, comprising: performing maintenance on the bypassed modular power converter after bypassing thebypassed modular power converter.
21. The method of claim 18, in which the bypassed modular power converter is bypassed using a mechanical switch.
22. The method of claim 21, in which the mechanical switch is external to a server tray containing the bypassed modular power converter and the mechanical switch is configured to automatically bypass the bypassed modular power converter when the server tray is removed from a server rack.
23. The method of claim 18, in which the bypassed modular power converter is bypassed using an electrical relay, an electrical contactor, or a solid-state switch.
24. The method of claim 18, comprising: providing isolation to the DC load using respective transformers of the modular power converters.
25. The method of claim 18, comprising: storing back-up power for the DC load in respective capacitors of the modular power converters.
26. The method of claim 18, comprising: storing back-up power for the DC load in respective batteries of the modular power converters.
27. The method of claim 18, in which converting AC power to DC power using the series cascade of modular power converters comprises implementing a phase shifted control solution for AC-to-DC power conversion.
28. The method of claim 18, in which converting AC power to DC power using the series cascade of modular power converters comprises implementing a clamped, level-shifted control solution for AC-to-DC power conversion.
29. The method of claim 18, in which the DC load includes a server installed in a server rack.
30. A system comprising: a first AC-to-DC converter with AC terminals connected in series with multiple AC-to- DC converters between terminals of an AC power source; a bypass circuitry connected to the AC terminals, wherein the bypass circuitry is configured to be a short circuit of the AC terminals in a bypass mode and to be open circuit in a normal operating mode; a first energy storage device connected to DC terminals of the first AC-to-DC converter; and a first DC-to-DC converter with input terminals connected to the first energy storage device and output terminals connected to a DC load.
31. The system of claim 30, in which the bypass circuitry includes a mechanical switch.
32. The system of claim 31 , in which the mechanical switch is external to a server tray containing the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter and the mechanical switch is configured to automatically transition the bypass circuitry to the bypass mode when the server tray is removed from a server rack.
33. The system of claim 30, in which the bypass circuitry includes an electrical relay, an electrical contactor, or a solid-state switch.
34. The system of claim 33, in which the bypass circuitry includes fault detection circuitry and is configured to automatically transition to the bypass mode when a fault is detected in the first AC-to-DC converter, the first energy storage device, or the first DC-to-DC converter.
35. The system of claim 30, in which the bypass circuitry includes components external to a server tray containing the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter.
36. The system of claim 30, in which the output terminals of the first DC-to-DC converter are connected in parallel with multiple DC-to-DC converters between terminals of the DC load.
37. The system of claim 30, in which the first DC-to-DC converter includes an isolation component.
38. The system of claim 37, in which the isolation component of the first DC-to-DC converter includes a transformer.
39. The system of claim 30, in which the first AC -to-DC converter includes an isolation component.
40. The system of claim 30, in which the first AC -to-DC converter includes four switches connected in an H-bridge topology.
41. The system of claim 40, in which the four switches are MOSFETs.
42. The system of claim 30, in which the first AC -to-DC converter, the first energy storage device, and the first DC-to-DC converter are components of a first modular power converter contained within a housing that exposes the AC terminals of the first AC-to-DC converter and the output terminals of the first DC-to-DC converter.
43. The system of claim 30, in which the first AC-to-DC converter, the first energy storage device, and the first DC-to-DC converter are components of a first modular power converter that are mounted on a circuit board along with a first controller of the first modular power converter that is configured to control switching in the first AC-to-DC converter and in the first DC-to-DC converter.
44. The system of claim 43, in which the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter are also components of respective modular power converters with components that match the components of the first modularpower converter.
45. The system of claim 44, in which the AC power source is one phase leg of a multi -phase AC power line, and AC power on another phase leg of the multi -phase AC power line is also converted using a series cascade of modular power converters with components that match the components of the first modular power converter, wherein output terminals of respective DC-to- DC converters in the series cascade of modular power converters are connected in parallel with the output terminals of the first DC-to-DC converter.
46. The system of claim 44, comprising a processing apparatus configured to: transmit control signals to the first controller and respective controllers of the respective modular power converters that include the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter, to cause the multiple AC-to-DC converters connected in series with the AC terminals of the first AC-to-DC converter to coordinate to convert AC power from the AC power source to energy stored in the first energy storage device and respective energy storage devices of the respective modular power converters.
47. The system of claim 46, in which the processing apparatus commands the first controller and respective controllers of the respective modular power converters to implement a phase shifted control solution for AC-to-DC power conversion.
48. The system of claim 46, in which the processing apparatus commands the first controller and respective controllers of the respective modular power converters to implement a clamped, level-shifted control solution for AC-to-DC power conversion.
49. The system of claim 30, in which the first energy storage device is a capacitor.
50. The system of claim 30, in which the first energy storage device is a battery.
51. The system of claim 30, in which the DC load includes a server installed in a server rack.
52. A system including a modular power converter comprising: a means for converting AC power to DC power with AC terminals connected in series with multiple AC-to-DC converters between terminals of an AC power source; a means for bypassing the means for converting AC power to DC power by shorting the AC terminals of the means for converting AC power to DC power; a capacitor connected to DC terminals of the means for converting AC power to DC power; and a means for converting DC power to DC power with magnetic isolation with input terminals connected to the capacitor, and output terminals connected in parallel with multiple DC-to-DC converters between terminals of a DC load.
53. The system of claim 52, in which the DC load includes a server installed in a server rack.
54. A system comprising: a housing that comprises a plurality of energy storage units, a plurality of data center loads, and a plurality of electrically connected power supply units, wherein: the plurality of electrically connected power supply units is configured as a plurality of smart integrated modules (SIMs) that are electrically connected to each other, and wherein each SIM of the plurality of SIMs is electrically connected to each energy storage unit of the plurality of energy storage units; and each energy storage unit of the plurality of energy storage units is configured to distribute electrical power to each data center load of the plurality of data center loads.
55. The system of claim 54, wherein each SIM of the plurality of SIMs includes at least one of a bi-directional or uni-directional DC-to-AC power converter, a bi-directional or a unidirectional DC-to-DC power converter, a battery management module, and a local controller.
56. The system of claim 55, wherein each SIM of the plurality of SIMs comprises one or more gate drivers configured to switch the bi-directional or the uni-directional DC-to-AC power converter on and off, and wherein the one or more gate drivers can be configured as an isolated gate driver, a bootstrap gate driver, or a charge pump gate driver.
57. The system of claim 54, wherein each SIM of the plurality of SIMs is adjacently disposed in relation to each energy storage unit of the plurality of energy storage units.
58. The system of claim 54, wherein each SIM of the plurality of SIMs is further configured to have a separate DC output that is connected to a separate data center load of the plurality of data center loads.
59. The system of claim 54, wherein each SIM of a first plurality of SIMs is further configured to connect a DC output bus associated with each SIM of the first plurality of SIMs in parallel or in series with a DC output bus associated with each SIM of a second plurality of SIMs.
60. The system of claim 59, wherein each data center load of the plurality of data center loads is electrically connected to the DC output bus associated with each SIM of the first plurality of SIMs or the DC output bus associated with each SIM of the second plurality of SIMs at an output of each SIM of the plurality of SIMs.
61. The system of claim 54, wherein each data center load of the plurality of data center loads is configured to: accept the electrical power at an isolated DC-to-DC converter; and reduce a voltage level to a predefined level to provide the reduced voltage level to a printed circuit board, wherein each data center load of the plurality of data center loads includes the printed circuit board.
62. The system of claim 54, wherein each SIM of the plurality of the SIMs has a regulating DC-to-DC converter connected between each energy storage unit of the plurality of energy storage units and each data center load of the plurality of data center loads.
63. The system of claim 54, comprising a voltage doubler circuit, wherein the voltage doubler circuit is configured to increase a voltage level at an AC power side associated with each SIM of the plurality of SIMs.
64. The system of claim 54, comprising one or more uninterrupted power supply units configured to use a same energy storage unit from the plurality of energy storage units in a power conversion process from a grid associated with each data center load of the plurality of data center loads.
65. The system of claim 54, wherein each SIM of the plurality of SIMs is further configured to control one or more local variables, in an associated battery energy storage and in the SIM while performing one or more power conversions, and wherein the one or more local variables includes a state of charge, a temperature, a state of health, or a combination thereof.
66. The system of claim 54, wherein each SIM of the plurality of SIMs is further configured to balance a state of charge of one or more associated modules based on a switching sequence in relation to the plurality of the SIMs.
67. The system of claim 54, wherein each SIM of the plurality of the SIMs communicates with the plurality of the SIMs or a central controller to determine a switching sequence.
68. The system of claim 54, wherein each SIM of the plurality of the SIMs balances a state of charge of one or more cells of each SIM of the plurality of SIMs while performing one or more system functionalities.
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