Universal battery integration module

Abstract

A modular battery integration module (BIM) connects a battery to a hybrid or electric power system. The BIM includes a battery terminal, a system terminal, a primary control circuit, and a switching circuit comprising a plurality of core modules that can be configured in series, parallel, or combination series and parallel connections. Each core module has a power stage circuit with solid-state switches and can be controlled independently by the primary control circuit. The BIM can further include a driver-based software framework configured to receive a driver defining a battery management system (BMS) interface configuration, enabling the BIM to communicate with and operate with different third-party battery types without modification of firmware. The BIM may be deployed as part of a Universal Power System Integration Platform (UPSIP) together with other Universal Integration Modules (UIMs) and a Power Supervisory Controller (PSC) for applications, including automotive, aerospace, and stationary energy systems.

Description

[0001] UNIVERSAL BATTERY INTEGRATION MODULE

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS The present application claims priority to U.S. Provisional Patent Application No.

[0003] 63 / 780,051 filed March 28, 2025, to U.S. Provisional Patent Application No. 63 / 793,510 filed April 23, 2025, and U.S. Provisional Patent Application No. 63 / 868,824 filed August 22, 2025, the entire contents of each of which, including appendices, are incorporated hy reference herein.

[0004] FIELD

[0005] The present invention relates generally to battery integration systems and high-voltage power distribution units, and more particularly to modular, software-configurable battery integration modules and universal integration module architectures for hybrid and electric power systems.

[0006] BACKGROUND

[0007] Battery integration systems and high-voltage power distribution units are commonly used across aerospace, automotive, and stationary energy markets to manage power delivery, safety, and monitoring between battery packs and the rest of the powertrain. These systems are typically referred to as Battery Disconnect Units (BDUs), Battery Power Distribution Units (BPDUs), or Battery Power Management Units (BPMUs). While these products serve similar baseline functions - connecting / disconnecting high-voltage (HV) batteries, providing precharge capabilities, and housing fuses or contactors - they tend to be application-specific, fixed in rating, and relatively inflexible in form factor and integration capability.

[0008] Most systems are designed with fixed voltage and current ratings, minimal software flexibility, and limited compatibility with third-party or in-house BMS platforms or missionspecific hardware. Many lack advanced EMI robustness, real-time reconfigurability, or integration-friendly interfaces necessary for modem hybrid-electric aircraft or highly variable mobile platforms, particularly in environments with a lot of switching noise from a large number of electric motors (e.g., for propellers). This gap in adaptability, integration flexibility, and configuration scalability leaves a clear opportunity for more universal and modular battery integration systems.

[0009] SUMMARY

[0010] A modular and software configurable battery integration module (BIM) is presented herein.Some embodiments of the BIM can be configured as a replacement for BDUs, BPDUs, and / or BPMUs in a hybrid or electric power system. The BIM preferably includes a modular open systems architecture (MOSA) which includes modular hardware that can be configured for a variety of system power levels and a driver-friendly software framework designed to support configurable “drivers” for integration with third-party battery packs or battery strings. The BIM is one member of a family of Universal Integration Modules (UIMs) that share a common core module architecture, standardized enclosure design, and driver-based software framework, and may be deployed as part of a Universal Power System Integration Platform (UPSIP) together with other UIMs and a Power Supervisory Controller (PSC). The BIM can be configured for various industry applications and can be sold as an integrated product, as a kit for constructing a BIM, or modular components of the BIM can be sold separately. The core module can also be sold as a standalone product.

[0011] In one embodiment, a BIM includes a battery terminal, a system terminal, a switching circuit, and a primary control circuit. The battery terminal is configured to couple to DC voltage terminals of a battery. The system terminal is configured to couple to DC voltage terminals of a hybrid or electric power system. The switching circuit provides a controllable electrical power path between the battery terminal and the system terminal. The switching circuit includes core modules each forming a respective controllable portion of the controllable electrical power path and connected in a series, parallel, or combination series and parallel configuration. Each core module includes battery-side connectors, system-side connectors, and a power stage circuit between the batteryside connectors and system-side connectors. The primary control circuit is in electrical communication with each of the core modules and is configured to provide a respective control signal to each respective core module to operate its power stage circuit to thereby control the respective controllable portion of the controllable electrical power path.

[0012] The power stage circuit of each core module can include at least one solid-state switch controllable to connect and disconnect the respective battery-side connectors to and from the respective system side connectors. The switching circuit can include at least one relay in the controllable electrical power path between the core modules and the battery terminal and / or between the core modules and the system terminal. The primary control circuit can be configured to first open the solid-state switch(es), and next, open the relay(s) to open the controllable electrical power path.

[0013] The power stage circuit of at least one of the core modules can include a resistive braking branch configured to be turned on (activated) to absorb excess power to protect the battery.

[0014] The switching circuit of at least one of the core modules can include an EMI filter in serieswith the power stage circuit and configured to reduce electromagnetic noise between the systemside connectors of the core module and the battery-side connectors of the core module.

[0015] The series, parallel, or combination series and parallel configuration of the core modules can be modified via software control by the controller and / or via reconfiguration of modular hardware of the BIM.

[0016] The primary control circuit can be configured to receive a driver that identifies a battery management system (BMS) interface configuration, a battery-specific configuration of the battery, operational parameters of the battery, or combination thereof. The primary control circuit can be configured to communicate with the battery using the BMS protocol, operate the core modules based on the battery-specific configuration, provide control commands to the BMS, or combination thereof.

[0017] The BIM can include a modular enclosure containing the switching circuit and primary control circuit and configured to be mechanically stackable with one or more additional BIMs. The BIM can be configured to connect in series and / or parallel with the additional BIM(s).

[0018] In another embodiment, a BIM kit includes a BIM enclosure and core modules. The BIM enclosure includes a battery terminal, a system terminal, a primary control circuit, and core slots. The battery terminal is configured to couple to DC voltage terminals of a battery. The system terminal is configured to couple to DC voltage terminals of a hybrid or electric power system. The primary control circuit includes data connections to the core slots. The core slots are configured to be connected in a series, parallel, or combination series and parallel connection. The core modules are configured to be inserted in the core slots to provide at least a portion of a controllable electrical power path between the battery terminal and the system terminal. The core modules are configured to be controlled by the primary control circuit via the data connections to the core slots. The BIM kit can otherwise include modular components for constructing a BIM described herein.

[0019] In another embodiment, a core module for a BIM comprises battery-side connectors, systemside connectors, a power stage circuit comprising solid-state switches, and a core module control circuit configured to generate drive signals for the solid-state switches and to autonomously detect and respond to fault conditions. The core module is configured to provide software-controlled isolation, precharge, and fault response.

[0020] In another embodiment, a BIM enclosure comprises a battery terminal, a system terminal, a plurality of core slots configured to receive core modules and connect them in series, parallel, or combination series and parallel connection, a primary control circuit with data connections to the core slots, an electromagnetic shield separating the primary control circuit from the core slots, and at least one relay in the controllable electrical power path.In another embodiment, a BIM implements a driver-based abstraction layer in which a primary control circuit receives, via a configuration data terminal, a driver defining a BMS interface configuration, enabling the BIM to operate with different third-party battery types by loading a corresponding driver without modification of firmware.

[0021] In another embodiment, a BIM stores a configurable operational profile comprising one or more state machine configurations and a fault response configuration defining a plurality of fault conditions and respective predetermined response actions. The configurable operational profile is replaceable via a configuration data terminal to adapt the BIM to different applications without firmware modification.

[0022] In another embodiment, a BIM includes a battery terminal, a system terminal, a switching circuit, and a primary control circuit. The battery terminal is configured to couple to DC voltage terminals of a battery. The system terminal is configured to couple to DC voltage terminals of a hybrid or electric power system. The switching circuit provides a controllable electrical power path between the battery terminal and the system terminal and includes a core module and at least one relay in the controllable electrical power path. The core module includes a power stage circuit having a high-side solid-state switch and a low-side solid-state switch each controllable by the primary control circuit to connect and disconnect the battery terminal to and from the system terminal. The primary control circuit is configured to first open the solid-state switches, and next, open the relay(s) to open the controllable electrical power path. The BIM can include only a single core module. The BIM, core module, switching circuit, and primary control circuit can otherwise include respective features as described herein in relation to a BIM having multiple core modules.

[0023] BRIEF DESCRIPTION OF THE DRAWINGS

[0024] While the specification concludes with claims, which particularly point out and distinctly claim the subject matter described herein, it is believed the subject matter will be better understood from the following description of certain examples taken in conjunction with the accompanying drawings, in which like reference numerals identify the same elements. The figures depict one or more implementations of the inventive devices, by way of example only, not by way of limitation.

[0025] FIG. 1 is a block diagram illustration showing the functionality and layout of an example BIM.

[0026] FIG. 2 is a block diagram illustration showing the functionality and layout of an example core module.

[0027] FIG. 3 is a schematic circuit diagram illustration showing the functionality and layout of an example switch circuit and controllable electrical power path.FIGS. 4A through 4C are block diagram illustrations showing functionality and layout of example core module power circuits where FIG. 4A is an illustration of a core module power circuit having a power stage circuit, FIG. 4B is an illustration of a core module power circuit having a power stage circuit and an EMI filter in series with the power stage circuit, and FIG. 4C is an illustration of a core module power circuit having a power stage circuit, a first EMI filter on the battery side of the power stage circuit and a second EMI filter on the system side of the power stage circuit.

[0028] FIG. 5A is a schematic circuit diagram illustration of an example power stage circuit. FIG. 5B is an illustration of an example layout of the power stage circuit of FIG. 5A including bus bars.

[0029] FIG. 6 is a schematic circuit diagram illustration of an example EMI filter circuit which can be in series with the power stage circuit as illustrated in FIG. 4B, including a battery-side EMI filter leg, a system-side EMI filter leg, and series inductors disposed in the horizontal current path.

[0030] FIG. 7 A is a schematic circuit diagram illustration of another example core module power circuit in which vertical circuit branches are disconnected from the horizontal current path within the core module and exposed as connectors for enclosure-level routing.

[0031] FIG. 7B is a block diagram illustration showing the functionality and layout of another example switch circuit including core modules having power circuits as illustrated in FIG. 7A connected in series via enclosure-level routing of the exposed connectors.

[0032] FIG. 7C is a schematic circuit diagram illustration of example core module connections as illustrated in FIGS. 7 A and 7B.

[0033] FIG. 8 is a state diagram illustrating example states of the BIM.

[0034] FIG. 9 is a schematic circuit diagram illustration of an example primary control circuit of the BIM.

[0035] FIG. 10A is a block diagram illustration of an example automotive vehicle power train including a BIM.

[0036] FIG. 10B is a block diagram illustration of an example BIM and battery configuration in an example hybrid electric vertical take-off and landing (hVTOL) aircraft.

[0037] FIG. IOC is a block diagram illustration of an example BIM and battery configuration in an example hybrid electric conventional take-off and landing (hCTOL) aircraft.

[0038] FIG. 10D is a block diagram illustration of a hybrid or electric power system illustrating example configurations of batteries with a BIM, an example generic integration module with a power source, an example generic integration module with a load, an example layered control system, and example electric motor loads.DETAILED DESCRIPTION

[0039] The following detailed description should be read with reference to the drawings, in which like elements in different drawings are identically numbered. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. The detailed description illustrates by way of example, not by way of limitation, the principles of the invention. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives, and uses of the invention, including what is presently believed to be the best mode of carrying out the invention.

[0040] As used herein, the terms “about” or “approximately” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of components to function for its intended purpose as described herein. More specifically, “about” or “approximately” may refer to the range of values ±10% of the recited value, e.g., “about 90%” may refer to the range of values from 81% to 99%.

[0041] FIG. 1 is a block diagram illustration showing the functionality and layout of an example BIM 100. The BIM 100 includes an enclosure 101 that houses and / or supports electrical and mechanical components for coupling a battery to a hybrid or electric power system. In the illustrated example, the BIM 100 includes a battery terminal 102 configured to couple to DC voltage terminals of a battery (e.g., BAT+ and BAT-), a charge terminal 104 configured to couple to a battery charging circuit (e.g. CHG+ and CHG-), and a system terminal 106 configured to couple to DC voltage terminals of the hybrid or electric power system (e.g., SYS+ and SYS-). The battery terminal 102, charge terminal 104, and system terminal 106 can each include a respective positive terminal and a respective negative terminal and can be implemented as any suitable high-current, high-voltage connection interface, such as stud terminals, bolt-down lugs, bus bar interfaces, and / or pluggable high-voltage connectors. In some embodiments, the battery terminal 102 provides the primary connection between the BIM 100 and the battery such that high-voltage power can be selectively delivered from the battery to the switching circuit 170 (FIG. 3) and to the system terminal 106, and / or received from the system (e.g., during regenerative operation) through the system terminal 106. The charge terminal 104 can provide an interface for a charger, external DC supply, or charge management subsystem and can be connected to the battery through the switching circuit and / or through dedicated charge-path components (e.g., the charge relay 124). The system terminal 106 can provide an interface to one or more loads and / ordownstream power distribution equipment of the hybrid or electric power system, such as one or more inverters, motor drives, DC / DC converters, and / or a high-voltage distribution bus.

[0042] The BIM 100 can further include one or more data and / or low-voltage interfaces such as a battery data terminal 103, a configuration data terminal 108, a control data terminal 110, and a low voltage power input terminal 112.

[0043] The battery data terminal 103 can provide communication between the BIM 100 and a battery management system (BMS) associated with the battery, such as for receiving battery state information (e.g., voltage, current, temperature, state of charge, state of health, fault / status flags) and / or sending commands (e.g., enable / disable, wake / sleep, charge limits), using any suitable communication medium and protocol (e.g., CAN, LIN, Ethernet, RS-485, UART, discrete I / O, or combinations thereof).

[0044] The configuration data terminal 108 can provide an interface for configuration, commissioning, and / or servicing of the BIM 100, such as loading or updating software, drivers, and / or battery-specific configuration parameters, and can support a wired and / or wireless interface via an external tool. The control data terminal 110 can provide an interface for operational control and supervisory communication with a vehicle controller, powertrain controller, charger controller, test stand controller, and / or other system-level controller, such as to exchange enable signals, contactor / relay commands, state information, fault codes, and / or operating mode commands.

[0045] The control data terminal 110 may additionally receive control parameters, test parameters, calibration data, diagnostic commands, combinations thereof, variations thereof, or alternatives thereto as understood by a person skilled in the art, from a power supervisory controller (PSC), a development computing device, or other external device. The low voltage power input terminal 112 can provide operating power to the primary control circuit 116 and associated low voltage components (e.g., the user interface 114), for example from a 12 V, 24 V, 28 V, or other suitable low-voltage supply, and can optionally include one or more power return / ground connections and / or additional low-voltage power outputs for auxiliary devices. The BIM 100 can include a user interface 114 (e.g., visual indicators such as LEDs and / or a display, touchscreen, buttons, etc.) to provide status, fault, configuration, and / or operating information and / or to support user input.

[0046] The BIM 100 can include a primary control circuit 116 that is in electrical communication with the terminals 102, 103, 104, 106, 108, 110, 112 and is configured to provide monitoring, communication, and control functions of the BIM 100, including control of high-voltage switching components described in further detail with respect to FIGS. 2-9. In some embodiments, the primary control circuit 116 is further configured to perform master battery management system(BMS) functions, including pack-level health monitoring, cell balancing coordination, thermal management, and fault management, either in place of or in addition to a separate master BMS board associated with the battery. When a battery includes an existing master BMS, the primary control circuit 116 may operate as a supervisory layer, communicating with the existing master BMS via the battery data terminal 103 while providing additional monitoring, control, and integration functions. The primary control circuit 116 can include one or more processors and non-transitory computer-readable medium in communication with the one or more processors with instructions thereon configured to cause the primary control circuit 116 to perform operations described herein.

[0047] A harness 118 can provide electrical interconnection between the primary control circuit 116 and internal components of the BIM 100 including components of a switching circuit 170, 170a as described in relation to FIGS.3 and 7B and elements of core modules 150 as described in relation to FIGS. 2 through 8.

[0048] The enclosure 101 can include an electromagnetic interference (EMI) shield 120 separating the primary control circuit 116 from higher voltage and / or higher noise switching components to reduce electromagnetic interference coupling to low-voltage circuitry. The BIM 100 can include one or more relays such as a battery side relay 122, a charge relay 124, and a load relay 126 to selectively connect and disconnect high-voltage power paths associated with the battery terminal 102, charge terminal 104, and system terminal 106, respectively. Because the primary control circuit 116 is configured to open the solid-state switches of the core modules 150 before opening the relays 122, 124, 126, the relays are not required to interrupt full load current and therefore do not require a breaking capacity corresponding to the maximum operating current of the controllable electrical power path, enabling the use of relays with reduced size and mass compared to contactors rated for full-load current interruption. The enclosure 101 can further include a plurality of core slots 130a-130f, which can receive corresponding core modules such as core modules 150 of FIGS. 2-3, alternatives thereto, or variations thereof as described herein or otherwise understood by a person skilled in the pertinent art informed by the disclosure herein.

[0049] The core slots 130a- 130f can include battery positive slot connectors 131 and battery negative slot connectors 132, system positive slot connectors 141 and system negative slot connectors 142, and data connectors 138 to couple power and data between the primary control circuit 116 and any inserted core modules. As illustrated, the BIM 100 can include six slots interconnected in a grid with a two-parallel by three-series series-parallel combination connection where slot 1 0a is parallel with slot 130d and connected to the positive slot connectors 1 1, slot 130b is parallel with slot 130e and in series with slots 130a and 130d, slot 130c is parallel withslot 130f and in series with slots 130b and 130e and connected to the battery negative slot connectors 132.

[0050] Preferably, the BIM 100 includes standardized and compatible enclosures 101 with standardized slots 130a-f to receive standardized core modules 150 (FIG. 2) to form BIMs 100 which are also standardized and compatible with each other. Preferably one core module 150 design (or a manageable number of core module designs, e.g., two, three, four, or five) can be utilized in a manageable number of enclosures 101 of different form factor (e.g., fewer than ten enclosures, preferably about four or five enclosures) in various combinations to suit the needs of the several embodiments described herein, variations thereof, and alternatives thereto as understood by a person skilled in the pertinent art informed by the disclosure herein. Each enclosure 101 design may provide for a different parallel / series configuration of core modules 150 (e.g., series x parallel: 2x4, 3x1, etc.). The BIMs 100 may further be combined to form other series x parallel combinations of core modules to meet the wide range of power needs presented in the below embodiments. Configurations of enclosures and core modules may be sold as a kit with the correct enclosure and number of modules to meet the specific needs of a given application.

[0051] FIG. 2 is a block diagram illustration showing the functionality and layout of an example core module 150. The core module 150 can be configured to be installed in a corresponding core slot 130 (FIG. 1) of the BIM 100 to form at least a portion of the switching circuit 170 (FIG. 3). The core module 150 can include a positive battery-side connector 151, a negative battery-side connector 152, a positive system connector 161, and a negative system connector 162. The connectors 151, 152, 161, 162 are configured to be connected to in series, parallel, or combination series and parallel connection to other core modules 150 such as illustrated in FIGS. 1, 3, 7A-C, otherwise described herein, or understood by a person skilled in the pertinent art infomred by the disclosure herein. The core module 150 can include additional power connectors such as described in greater detail with respect to FIGS. 7A-7C.

[0052] The core module 150 can include a core module power circuit 154 (e.g., core module power circuit 154a, 154b, 154c, 154d of FIGS. 4A-4C and 7A-7C) providing a controllable portion of a controllable electrical power path between battery-side connectors 151, 152 and system-side connectors 161, 162 of the core module 150. The connectors 151, 152, 161, 162 can each include exposed conductors configured to be connected to interconnects within the enclosure 101 to form a series, parallel, or combination series and parallel connection.

[0053] The core module 150 can further include a core module control circuit 156 configured to receive one or more control signals from the primary control circuit 116 (FIG. 1) and to control operation of the core module power circuit 154. For instance, the core module control circuit 156can be configured to generate drive signals for one or more solid-state switches of the power stage circuit 166 (FIGS. 5A-5B) based on control signals from the primary control circuit 116. The core module control circuit 156 can further be configured to provide data to the primary control circuit 116 including information regarding the operation of the core module 150 such as sensor data, fault condition, etc. In some embodiments, the core module control circuit 156 is further configured to autonomously detect and respond to local fault conditions based at least in part on sensor measurements within the core module 150, independent of or in addition to commands from the primary control circuit 116. The primary control circuit 116 can be contained within the enclosure 101. The core module control circuit 156 can include one or more processors and non-transitory computer-readable medium in communication with the one or more processors with instructions thereon configured to cause the core module control circuit 156 to perform operations described herein.

[0054] The core module 150 can include a control connector 160 (e.g., a pluggable connector) configured to electrically couple to a corresponding data connector 138 (FIG. 1) such that the primary control circuit 116 can provide a respective control signal to the core module 150 and can receive data from the core module 150. The core module 150 can include a sensor connector 164 for providing raw sensor data from one or more sensors (e.g., voltage, current, temperature, and / or other sensors as described with respect to FIGS. 5A and 5B) to the primary control circuit 116.

[0055] The core module 150 can include a core printed circuit board (PCB) 158 supporting at least portions of the core module control circuit 156 and / or other circuitry of the core module power circuit 154. The core module power circuit 154 can include bus bars 176 providing low-impedance current paths between the connectors 151, 152, 161, 162 and the core module power circuit 154. The bus bars 176 can be implemented using laminated conductors, embedded conductors within the PCB 158 (e.g., deep copper), and / or discrete bus stmctures mechanically coupled to the PCB 158. In this manner, each core module 150 can be controlled by the primary control circuit 116 to connect and disconnect its battery-side connectors 151, 152 to and from its system-side connectors 161, 162 to thereby control a respective controllable portion of the controllable electrical power path between the battery terminal 102 and system terminal 106 as described herein.

[0056] FIG. 3 is a schematic circuit diagram illustration showing the functionality and layout of an example switching circuit 170 which provides a controllable electrical power path between the battery terminal 102 and the system terminal 106 and can also provide a controllable electrical power path between the battery terminal 102 and the charge terminal 104. The charge terminal 104 is illustrated separately from the system terminal 106 in FIGS. 1 and 3; however, in some embodiments, the charge terminal 104 and system terminal 106 may be one in the same. Theswitching circuit 170 can be contained within the enclosure 101 (FIG. 1).

[0057] In the illustrated example, the switching circuit 170 includes a plurality of core modules 150 that are electrically interconnected in a combination series-and-parallel configuration, a battery relay 122 connecting the core modules 150 to the battery terminal 102, a charge relay 124 connecting the core modules 150 to the charge terminal 104, and a system relay 126 connecting the core modules 150 to the system terminal 106. Relays 122, 124, 126 can provide galvanic isolation and / or to support additional safety and service modes as described herein. In some embodiments, the battery relay 122 can be omitted for weight and cost savings. In some embodiments, the system and charge relays 124, 126 can be consolidated in a single relay, the output of which can be routed to separate system and charge terminals 104, 106 or a consolidated system / charge terminal.

[0058] As illustrated, the core modules 150 are arranged in columns and rows so that every core module in a given row is connected in parallel with every other core module in that row, and the rows are connected in series so that every core module in a give row is in series with all core modules in other rows. The positive battery-side connectors of the core modules 150 in the top row are connected to a positive battery connector BAT+ via the battery relay 122 and battery terminal 102. The positive system-side connectors of the core modules 150 in the top row are connected to positive charge CHG+ and system SYS+ connections via the charge relay 124 and charge terminal 104 and via the system relay 126 and system terminal 106. The negative batteryside connectors of the core modules 150 in the bottom row are connected to a negative battery connector BAT- via the battery relay 122 and battery terminal. The negative system-side connectors of the core modules 150 in the bottom row are connected to negative charge CHG- and system SYS- connections via the charge relay 124 and charge terminal 104 and via the system relay 126 and system terminal 106. Core modules 150 in middle rows are connected in series with the core modules 150 directly above and below.

[0059] Referring collectively to FIGS. 1-3, the core modules 150 can be physically arranged in a grid layout as illustrated. Additionally, or alternatively, the core modules may be physically stackable so that series, parallel, or combination series and parallel connections can be made between interlocking connections of core modules physically stacked on top of each other, with the bottom core module 150 being connected to a slot 130. The number of core modules in parallel and in series can be modified to meet power system requirements of the hybrid or electric power system powered by the battery. The slot arrangement can be modified based on the form factor of the enclosure 101.

[0060] While FIGS. 1 and 3 show every core module 150 connected in both series and parallel, insome embodiments, selected interconnections between core modules 150 can be omitted to save weight and space and / or provide desired functionality.

[0061] The battery slot connectors 131, 132, system slot connectors 141, 142, and interconnects between the core slots 130 can include conductive structures such as bus bars, jumpers, and / or a backplane. A BIM kit may allow for the rearrangement of the battery slot connectors 131, 132, system slot connectors 141, 142, and interconnects between the core slots 130 to allow a customer to configure the core modules in the desired series, parallel, or combination series and parallel connection. Alternatively, some or all of the battery slot connectors 131, 132, system slot connectors 141, 142, and interconnects between the core slots 130 can be fixed; and the customer can configure the core modules in the desired series, parallel, or combination series and parallel connection based on selected population of core modules 150 into slots 130 and / or stacking of core modules 150 over selected slots 130. The core modules 150 can be substantially identical and interchangeable with each other.

[0062] Each core module 150 forms a respective controllable portion of the controllable electrical power path and can be controlled to connect and disconnect its respective battery-side connectors 151, 152 to and from its respective system-side connectors 161, 162, for example by opening and closing one or more solid-state switches of the respective power stage circuit (e.g., power stage circuit 166 of FIGS. 5A-5B). The primary control circuit 116 can provide a respective control signal to each core module 150 such that selected ones of the core modules 150 can be operated (e.g., turned on, turned off, and / or modulated) independently of other core modules, thereby enabling selective connection / disconnection of one or more core modules.

[0063] The selective operation of core modules 150 can be based at least in part on an operating condition of the hybrid or electric power system. For example, under low -cunent conditions, such as battery precharge or idle condition of the power hybrid or electric power system, it may be advantageous (e.g., reduce energy consumption by the BIM) to reduce the number of core modules 150 which provide a parallel current path through the BIM; in which case the BIM may deactivate one or more core modules to eliminate parallel current paths.

[0064] The selective operation of core modules 150 can be based at least in part on sensor data of the core module 150. For instance a faulted core module may be deactivated while the BIM 100 maintains power delivery through another parallel branch by continuing to operate one or more of the remaining core modules. In some embodiments, the core module 150 may include a processor in the core module control circuit 156 configured to operate the core module power circuit 154 based at least in part on sensor data of the core module 150, and may be configured to communicate the modified operation and / or sensor data to the primary control circuit 116 via the controlconnector 160.

[0065] FIGS. 4A through 4G are block diagram illustrations showing functionality and layout of example core module power circuits 154a-c where FIG. 4A is an illustration of a core module power circuit 154a having a power stage circuit 166, FIG. 4B is an illustration of a core module power circuit 154b having a power stage circuit 166 and an EMI filterl 68 in series with the power stage circuit 166, and FIG. 4C is an illustration of a core module power circuit E54c having a power stage circuit 166, a first EMI filter 168a on the battery side of the power stage circuit 166 and a second EMI filter 168b on the system side of the power stage circuit 166. The core module power circuit can have alternative, such as illustrated in FIG. 7A, otherwise described herein, variations thereof, or combinations thereof, as understood by a person skilled in the pertinent art informed by the disclosure herein.

[0066] FIG. 5 A is a schematic circuit diagram illustration of an example power stage circuit 166 of the core module 150. The power stage circuit 166 can include a high-side switch circuit 146 in an electrical path between the positive battery-side connector 151 and the positive system-side connector 161 of the core module 150 (FIGS. 4A-4C), and a low-side switch circuit 148 in an electrical path between the negative battery-side connector 152 and the negative system-side connector 162 of the core module (FIGS. 4A-4C). In this manner, the power stage circuit 166 can be controlled to selectively couple, decouple, and / or modulate the electrical connection between the battery and the hybrid or electric power system through the core module 150.

[0067] The high-side switch circuit 146 and the low-side switch circuit 148 can include one or more solid-state switches (e.g., switches SW1, SW2, SW3). The solid-state switches can include any suitable controllable semiconductor devices such as MOSFETs (e.g., SiC MOSFETs), IGBTs, or combinations thereof, optionally with associated anti-parallel diodes and / or body diodes. In some embodiments, the solid-state switches are arranged in one or more half-bridge configurations, phase-leg configurations, or switch-pair configurations such that, when turned on, the core module 150 provides a low-impedance current path between the battery-side connectors 151, 152 and the system-side connectors 161, 162, and when turned off, the core module 150 interrupts current flow through its portion of the controllable electrical power path.

[0068] The power stage circuit 166 can further include a precharge circuit 144 configured to control inrush current and / or to charge downstream capacitance (e.g., capacitance at the system terminal 106, an inverter DC link, and / or other bus capacitance) prior to operating the power stage circuit 166 in a fully energized mode. In some embodiments, the precharge circuit 144 includes a precharge resistor and one or more controllable devices (e.g., a solid-state switch or relay) to selectively couple the battery-side connectors 151, 152 to the system-side connectors 161, 162through the precharge resistor. The precharge circuit 144 can be controlled by the primary control circuit 116 and / or by the core module control circuit 156 such that precharge occurs before closing the main current path 145 through the high-side switch circuit 146 and the low-side switch circuit 148.

[0069] In some embodiments, the power stage circuit 166 further includes a resistive braking branch 174 configured to be selectively activated to dissipate excess power, for example to protect the battery and / or other powertrain components during a fault condition, an overvoltage condition, regenerative operation, or other operating conditions to divert energy away from the battery and / or away from sensitive downstream components for battery and / or system protection. The resistive braking branch 174 can include one or more resistive elements and one or more controllable devices (e.g., one or more solid-state switches and / or a relay) to selectively connect the resistive element(s) to the circuit. In some embodiments, the resistive braking branch 174 is controlled by the primary control circuit 116 based at least in part on sensor measurements, and additionally or alternatively, can be triggered locally by the core module control circuit 156. For instance, the resistive braking branch 174 can be activated by the primary control circuit 116, core module control circuit 156, or combination thereof in response to a detected overcurrent, overvoltage, overheating condition, or other condition as understood by a person skilled in the pertinent art informed by the disclosure herein.

[0070] The power stage circuit 166 can include one or more sensors such as voltage sensors (e.g., VI and V2), current sensors (e.g., Al and A2), temperature sensors, and / or other sensors configured to measure electrical and / or thermal characteristics of the core module 150. For example, the sensor(s) can measure voltage at one or more nodes on the battery side and / or system side of the power stage circuit 166, measure current through one or more switch circuits 146, 148, and / or measure temperature of one or more switches SW1, SW2, SW3, SW4 and / or associated bus structures 176 (FIG. 5B). Sensor measurements can be provided to the primary control circuit 116 (e.g., via the sensor connector 164, FIG. 2) and / or to the core module control circuit 156. In response to a fault condition measured by the sensor(s), the core module 150 can provide a fault signal to the primary control circuit 116 and / or can autonomously modify operation of the power stage circuit 166 (e.g., opening one or more switches, limiting current, entering a protective mode, and / or activating the resistive braking branch 174) to provide fast local protection.

[0071] The core module control circuit 156 can be configured to receive a respective control signal from the primary control circuit 116 and to generate drive signals for operating the solid-state switches of the high-side switch circuit 146 and the low-side switch circuit 148. In some embodiments, the primary control circuit 116 provides switching commands such as on / offcommands, duty cycle commands, other modulation commands, or combinations thereof to safely drive the gates of the solid-state switches and achieve desired system operation. The primary control circuit 116 can coordinate the operation of the precharge circuit 144, the main current path through the switch circuits 146, 148, and the resistive braking branch 174, for example as part of a state machine (FIG. 8) and / or based on battery data received from a battery management system via the battery data terminal 103 and sensor measurements received from the core modules 150.

[0072] The power stage circuit 166 as illustrated in FIG. 5 A represents one example embodiment. In alternative embodiments, the power stage circuit 166 may include additional or different switching elements, energy storage elements (e.g., inductors), and / or different switch topologies to enable additional functionality, such as DC-DC voltage conversion (e.g., boost, buck, or buckboost operation), bidirectional power flow, or other power conditioning functions, while maintaining the core module’s standardized battery-side connectors, system-side connectors, and interface with the primary control circuit 116.

[0073] FIG. 5B is an illustration of an example layout of the power stage circuit 166 of FIG. 5 A including bus bars 176, which in various embodiments can be implemented as laminated conductors, embedded conductors within the core PCB (e.g., deep copper), and / or discrete bus structures. The bus bars 176 can provide low-impedance and / or low-inductance current paths through the core module power circuit 154. As illustrated, the bus bars 176 extend between the switch circuits 146, 148 and the battery-side and system-side connectors 151, 152, 161, 162. The PCB can be modified to include an EMI filter 168, and the bus bars 176 can connect elements of the EMI filter 168 as understood by a person skilled in the pertinent art informed by the disclosure herein.

[0074] FIG. 6 is a schematic circuit diagram illustration of an example EMI filter circuit 168 which can be in series with the power stage circuit 166 as illustrated in FIG. 4B. In some embodiments, each core module 150 includes a respective EMI filter circuit 168 disposed electrically between the system-side connectors 161, 162 and the power stage circuit 166 (and / or between the battery -side connectors 151, 152 and the power stage circuit 166) and configured to reduce 152 electromagnetic noise and other switching transients conducted between the system-side connectors 161, 162 to the battery-side connectors 151, 152. The EMI filter circuit 168 can include one or more capacitors, inductors, and / or resistive elements arranged to provide differential-mode filtering and / or common-mode filtering, such as series inductors on one or both conductors and one or more capacitors coupled across the conductors and / or to chassis / ground, as understood by a person skilled in the pertinent art informed by the disclosure herein. As illustrated, the EMI filter includes a battery-side EMI filter leg 178, a system-side EMI filter leg 179, and a coupled inductorL3 between the battery-side EMI filter leg 178 and system-side EMI filter leg 179. Alternative EMI filter configurations can be implemented as understood by a person skilled in the pertinent art informed by the disclosure herein.

[0075] The EMI filter circuit 168 further includes series inductors LI and L2 disposed in the positive and negative conductors of the horizontal current path, each providing series inductance for differential-mode filtering, along with a coupled inductor L3 providing common-mode filtering between the battery-side and system-side filter legs. In alternative embodiments of the core module power circuit 154c (FIG. 4C), the first and second EMI filters 168a, 168b may each comprise variations of the filter topology illustrated in FIG. 6, subsets of components thereof, or alternative filter topologies as understood by a person skilled in the pertinent art informed by the disclosure herein. In some embodiments, the EMI filter functions may be partially or fully integrated with the power stage circuit 166, including embodiments where additional switching elements participate in both power conversion and filtering functions.

[0076] FIG. 7A is a schematic circuit diagram illustration of another example core module power circuit L54d in which the high-side switch circuit 146, low-side switch circuit 148, and EMI filter legs 178 are disconnected from each other within the core module 150. In addition to the batteryside connectors 151, 152 and system-side connectors 161, 162, the core module 150 can include a resistive braking branch positive connector 173, a resistive braking branch negative connector 175, system-side EMI filter leg positive connector 167, and system-side EMI filter leg negative connector 169. FIG. 7A is an illustration of a specific example in which the core module 150 includes a power stage circuit 166 which has a high-side switch circuit 146, low-side switch circuit 148, resistive braking branch 174 configured as illustrated in FIG. 5A or variation thereof; and the EMI filter is in series with the power stage circuit 166 as illustrated in FIG. 4B and includes EMI filter legs 178, 179 as illustrated in FIG. 6 or variation thereof. The core module power circuit 154d can be alternatively configured to provide separate positive and negative connections to various circuit branches that extend in parallel across the battery-side connectors 151, 152 and / or system-side connectors 161, 162 as understood by a person skilled in the pertinent art informed by the disclosure herein. The additional connectors 173, 175, 167, 169 allow for more possibilities for parallel and series connections of the core modules.

[0077] FIG. 7A further illustrates a high-side series inductor section 188 disposed in the positive conductor of the horizontal current path of the core module 150, comprising a series inductor LI and a top winding of a coupled inductor L3; and a low-side series inductor section 190 disposed in the negative conductor of the horizontal current path, comprising a series inductor L2 and a bottom winding of the coupled inductor L3. A high-side intermediate connector 192 is providedbetween the high-side switch circuit 146 and the high-side series inductor section 188, and a low-side intermediate connector 193 is provided between the low-side switch circuit 148 and the low-side series inductor section 190. The battery-side EMI filter leg 178 includes a battery-side EMI filter leg positive connector 194 and a battery-side EMI filter leg negative connector 195. The system-side EMI filter leg 179 positive connector 167 and negative connector 169 connect the system-side EMI filter leg to the enclosure-level routing. In the core module power circuit 154d, all connections between vertical branches (174, 178, 179) and the horizontal current path are made at the enclosure level by default, enabling flexible enclosure-level routing to achieve different series, parallel, or mixed electrical topologies. In some embodiments, the core module 150 may include one or more configurable connections, such as jumpers, removable conductive links, or switches, to optionally connect one or more vertical branch endpoints to the horizontal rails within the core module itself, for example when the core module is positioned at an end of a series chain and enclosure-level termination is not available or practical.

[0078] FIG. 7B is a block diagram illustration showing the functionality and layout of another example switching circuit 170a including core modules having power circuits E54d as illustrated in FIG. 7A in an alternative series and parallel connection. The system-side connectors 161, 162 of the top core module power circuit 154d are connected to the battery-side connectors 151, 152 of the bottom core module power circuit 154d to put the high-side switch circuits 146 in series with each other and the low-side switch circuits 148 in series with each other. The system-side EMI filter leg negative connector 169 and the resistive braking branch negative connector 175 of the top core module power circuit 154d are connected to the system-side EMI filter leg positive connector 167 and the resistive braking branch positive connector 173 of the bottom core module power circuit 154d to put the resistive braking branches 174 in series with each other, the battery -side EMI filter legs 178 in series with each other, and the system-side EMI filter legs 179 in series with each other. The high-side series inductor sections 188 are connected in series with each other along the positive horizontal rail, and the low-side series inductor sections 190 are connected in series with each other along the negative horizontal rail. All connections between vertical branch connectors (173, 175, 192, 193, 194, 195, 167, 169) of adjacent core modules are made at the enclosure level (e.g., within the enclosure 101).

[0079] FIG. 7B represents one embodiment of enclosure-level routing; alternative embodiments may connect the endpoints of one or more vertical branches to intermediate nodes (192, 193) or rail connections of different core modules in the series chain, resulting in different effective circuit topologies. The specific enclosure-level routing configuration can be selected based on desired voltage stress distribution, filtering performance, or other design considerations. In oneembodiment, the vertical branch endpoints are disconnected from the horizontal rails within each core module and the enclosure-level conductive interconnections chain the vertical branches in series using an S-shaped routing path - connecting the bottom connector of a first core module’s vertical branch to the top connector of an adjacent core module’s vertical branch, and repeating across the series chain - such that both the horizontal switching elements and the vertical branch elements each experience only a fraction of the total enclosure voltage, distributing voltage stress across all modules in the chain.

[0080] FIG. 7C is a schematic circuit diagram illustration of example core module connections as illustrated in FIGS. 7A and 7B. The BIM can include a number n of core modules 150 connected in a similar configuration as shown in FIG. 7B to result in the series connection of each the n circuit branches (e.g., 146a to 146n, 148a to 148n, 174a to 174n, 178a to 178n, and 179a to 179n).

[0081] FIG. 7C further illustrates the series connection of the high-side series inductor sections 188a to 188n along the positive horizontal rail and the low-side series inductor sections 190a to 190n along the negative horizontal rail. The vertical branch chains (174a-n, 178a-n, 179a-n) are shown connected at corresponding intermediate nodes of their respective core modules; however, the enclosure-level routing may alternatively connect the endpoints of one or more vertical branches to intermediate nodes (192, 193) or rail connections of different core modules in the series chain, as described with respect to FIG. 7B.

[0082] FIG. 8 is a state diagram illustrating example states of the BIM 100. In some embodiments, the primary control circuit 116 is configured to control operation of the switching circuit 170 according to a state machine including at least a precharge state, an energized state, and a fault state. The state machine can include a standby state and a system activate state. Transitions between the states can be based at least in part on data from one or more sensors (e.g., voltage, cunent, and / or temperature sensors) of one or more of the core modules 1 0. For example, in the precharge state the primary control circuit 116 can operate one or more precharge circuits 144 (FIG. 5A) and / or control operation of one or more solid-state switches of the power stage circuits 166 to manage system startup and limit inrush current, and upon satisfaction of one or more precharge conditions determined from sensor data (e.g., DC link voltage reaching a threshold and / or current being below a threshold) the state machine can transition to the energized state in which the controllable electrical power path is enabled for normal power delivery. In response to a detected fault condition based on sensor data (e.g., overvoltage, overcurrent, and / or overtemperature), the state machine can transition to the fault state in which the primary control circuit 116 operates the switching circuit 170 to reduce risk to the battery and / or hybrid or electric power system, for example by opening one or more solid-state switches of one or more coremodules 150, opening one or more relays 122, 124, 126 (FIGS. 1 and 3), and / or activating a resistive braking branch 174 (FIG. 5A).

[0083] In some embodiments, the state machine further implements one or more software-configurable fail-safe modes, including loss-of-communication logic, such that in response to loss of communication with a system-level controller and / or an external computing device, the primary control circuit 116 operates the switching circuit 170 based at least in part on a customized fault response previously received via the configuration data terminal 108, for example by commanding one or more core modules 150 and / or one or more relays 122, 124, 126 to transition to a corresponding state. The state machine of FIG. 8 is a simplified representation of one example embodiment; in alternative embodiments, the primary control circuit 116 may implement additional states, sub-states, and / or transition conditions to support additional operating modes, diagnostic routines, mission-specific energy management strategies, or application-specific fault response behaviors.

[0084] In some embodiments, the primary control circuit 116 transitions the BIM 100 to a selected fail-safe state defined in software (e.g., maintaining a contactor / relay state, dropping to a standby state, initiating self-diagnostics, and / or transitioning to the fault state), thereby enabling missionspecific responses and enhanced fault resilience.

[0085] FIG. 9 is a schematic circuit diagram illustration of an example primary control circuit 116 of the BIM 100.

[0086] In the illustrated example, the primary control circuit 116 includes a processor 180 configured to execute program instructions stored in non-transitory memory (not shown) to implement monitoring, communication, and control functions described herein, including controlling operation of the switching circuit 170 and coordinating operation of the core modules 150 and relays 122, 124, 126. For example, the processor 180 can be configured to (i) provide respective control signals to respective core module control circuits 156 of the core modules 150 to operate respective power stage circuits 166, (ii) receive sensor measurements and fault indications from the core modules 150, (iii) exchange data with a battery management system (BMS) associated with a battery via the battery data terminal 103, (iv) exchange supervisory control parameters and / or status with a system- level controller via the control data terminal 110, (v) receive configuration data, drivers, operational parameters, and / or customized fault response instructions via the configuration data terminal 108, or combinations and sub-combinations thereof. The processor 180 may comprise any suitable processing device including a microcontroller, microprocessor, digital signal processor (DSP), field-programmable gate array (FPGA), system-on-chip (SoC), or combinations thereof.As illustrated, one or more gate drive cable(s) 181 provide one or more electrical connections between the primary control circuit 116 and one or more core modules 150 for conveying control signals, such as on / off commands, modulation commands, enable / disable commands, timing commands, and / or other switching commands, to the core module control circuit 156 of each core module 150 to control operation of the solid-state switches of the power stage circuit 166 (e.g., the high-side switch circuit 146 and low-side switch circuit 148). In some embodiments, the primary control circuit 116 is configured to coordinate a shutdown sequence in which the processor 180 first commands the core modules 150 (via the gate drive cable(s) 181) to open one or more solid-state switches to interrupt or substantially reduce current flow through the controllable electrical power path, and then commands opening of one or more relays 122 and / or 126 (and / or 124 depending on implementation) to provide galvanic isolation and / or an additional disconnection layer, thereby enabling the use of relays that are not required to interrupt full load current.

[0087] One or more sensor data cable(s) 182 provide one or more electrical connections between the primary control circuit 116 and sensors of the BIM 100, for example sensors disposed in or associated with the core modules 150 and / or sensors disposed elsewhere in the BIM 100. The sensor data cable(s) 182 can convey sensor measurements (e.g., voltage measurements, current measurements, temperature measurements, and / or status data) to the processor 180 for use in determining operating states (FIG. 8), evaluating conditions for precharge and energization, detecting faults, and selecting control actions. In response to a fault condition and / or a threshold condition determined from sensor measurements, the processor 180 can operate the switching circuit 170 by commanding one or more core modules 150 to open and / or limit current through their respective power stage circuits 166 and / or by commanding one or more relays 122, 124, 126 to open.

[0088] A relay control bus 183 provides one or more control connections between a relay driver 186 controlled by the processor 180 to drive actuation currents for the relays 122, 124, 126. The primary control circuit 116 can control opening and closing of the relays 122, 124, 126 based on control parameters received via the control data temrinal 110, based on battery data received via the battery data terminal 103, and / or based on sensor measurements received via the sensor data cable(s) 182. For example, the processor 180 can be configured to control operation of a charge relay 124 disposed between the switching circuit 170 and the charge terminal 104 based at least in part on a condition of the battery (e.g., BMS-reported status) and / or based at least in part on one or more sensor measurements of the BIM 100 (e.g., sensed voltage, cunent, and / or temperature conditions).

[0089] The primary control circuit 116 can further include one or more voltage regulators, such asa 5V regulator 184 and a 15V regulator 185 (or other suitable low- voltage regulators), configured to generate regulated supply rails for low- voltage electronics of the BIM 100. For example, the 5 V regulator 184 can supply logic-level circuitry such as the processor 180 and associated communications and interface circuitry, and the 15V regulator 185 can supply driver circuitry such as the relay driver 186 and / or provide an auxiliary supply for core module control-related circuitry and interfaces. In some embodiments, the regulators 184, 185 are powered from the low voltage power input terminal 112 and provide stable operation over expected supply variations of the hybrid or electric power system. In some embodiments, additional voltage regulators may be included to provide additional voltage domains as required by the primary control circuit 116 and associated peripheral components.

[0090] In some embodiments, the primary control circuit 116 implements a driver-based abstraction layer in which the processor 180 is configured to receive, via the configuration data terminal 108, a driver identifying a BMS interface configuration and / or a driver including a battery-specific configuration of the battery and operational parameters for the battery. The processor 180 can then communicate with the battery via the battery data terminal 103 using the BMS interface configuration identified by the driver, operate the plurality of core modules 150 based at least in part on the battery-specific configuration and / or operational parameters (e.g., precharge profiles, fault thresholds, timing configurations, current limits, and / or temperature limits), provide control commands to the BMS based at least in part on the driver, or combinations or sub combinations thereof. The BMS interface configuration may define one or more of: a communication protocol (e.g., CAN, Ethernet, UART, RS-485), message definitions, signal and command mappings, lookup tables, data formats and specifications, configuration parameters, command structures, or other information required for communicating with the BMS via the batlcry data terminal 103.

[0091] In some embodiments, the processor 180 is further configured to receive, via the configuration data terminal 108, a customized fault response instruction that defines a selected fail-safe response; and in response to loss of communication with the hybrid or electric power system via the control data terminal 110, the processor 180 operates the switching circuit 170 based at least in part on the customized fault response instruction, for example by commanding one or more core modules 150 and / or one or more relays 122, 124, 126 to transition to a corresponding safe state.

[0092] The gate drive cable(s) 181, sensor data cable(s) 182, relay control bus 183, and supply from the 15V regulator 185 can be routed through the harness 118. These collective connections are represented as data connectors 138 in FIG. 1.

[0093] FIG. 10A is a block diagram illustration of an example automotive vehicle power train 200including a BIM 100. In the illustrated embodiment, the BIM 100 is coupled to a battery 202 having a battery management system (BMS) 204, and the BIM 100 can exchange battery state information and / or commands with the BMS 204 via the battery data terminal 103 (FIG. 1). The BIM 100 is further coupled to a power train controller (PTC) 210, for example via the control data terminal 110 (FIG. 1), such that the PTC 210 can provide commands (e.g., enable / disable, mode selection, and / or power requests) and receive status and fault reporting from the BIM 100. The BIM 100 provides a controllable electrical power path between the battery 202 and downstream powertrain components, including inverters 207 and associated motors 208, wherein the inverters 207 can be configured to convert DC power from the battery 202 to AC power for driving the motors 208 and / or to convert AC power from the motors 208 to DC power during regenerative operation. The power train 200 can further include a charger 206 configured to charge the battery 202, for example via the charge terminal 104 (FIG. 1) of the BIM 100, and the BIM 100 can selectively couple the charger 206 to the battery 202 (e.g., via the charge relay 124 and / or via operation of one or more core modules 150 as described herein) based on one or more conditions and / or commands. The power train 200 can further include a DC / DC converter and 12V bus 212 configured to supply one or more low-voltage loads and / or a low- voltage electrical bus of the vehicle, wherein the DC / DC converter can receive power from the battery 202 through the BIM 100 and / or can provide low- voltage power for operation of low-voltage systems and auxiliary loads. The power train 200 can further include an engine system 214 (e.g., a combustion engine and associated electronics) which can be controlled by the PTC 210 and can provide mechanical power to the drivetrain and / or electrical power via a generator subsystem (not shown) depending on the vehicle architecture. In some embodiments, the BIM 100 supports hybrid and electric operating modes by selectively enabling, disabling, and protecting power flow between the battery 202 and the inverter 207, motor 208, charger 206, and DC / DC converter and 12V bus 212 based on commands from the PTC 210 and / or based on battery status from the BMS 204 and sensor data from the BIM 100.

[0094] FIG. 10B is a block diagram illustration of an example BIM 100 and battery configuration in an example hybrid electric vertical take-off and landing (hVTOL) aircraft. As illustrated, six batteries are connected in a 3 series x 3 parallel combination and each battery 202 includes a BMS. The BIM 100 is connected by a data connection to each BMS, and has a power connection to the terminals BAT+ I BAT- of the battery stack. The BIM 100 can provide an interface between the batteries 202 and the hybrid electric powertrain system of the hVTOL aircraft as described elsewhere herein.

[0095] FIG. 10C is a block diagram illustration of an example BIM 100 and battery 202configuration in an example hybrid electric conventional take-off and landing (hCTOL) aircraft. As illustrated, six batteries are connected in a parallel configuration and each battery 202 includes a BMS. The BIM 100 is connected by a data connection to each BMS, and has a power connection to the terminals BAT+ / BAT- of the battery stack. The BIM 100 can provide an interface between the batteries 202 and the hybrid electric powertrain system of the hCTOL aircraft as described elsewhere herein.

[0096] FIG. 10D is a block diagram illustration of a hybrid or electric power system illustrating example configurations of batteries 202 with a BIM 100, an example generic integration module 300a with a power source 216, an example generic integration module 300b with a load 218, an example layered control system, and example electric motor loads 208. The illustrated system is not intended to represent any specific application, but rather illustrate various components of a modular hybrid or electric power system that can be utilized as needed. The layered control system can include a power supervisory controller (PSC) 220, which can be configured as described in International Patent Application Number PCT / US2026 / 016891, incorporated by reference herein. The PSC 220 can be configured to communicate with a system controller 210 and second tier controller 219 as described in International Patent Application Number PCT / US2026 / 016891. Alternatively, the BIMs may be controlled by existing or simplified power train or system controllers, such as the PTC 210 illustrated in FIG. 10A, or other such controller as understood by a person skilled in the pertinent art informed by the disclosure herein.

[0097] FIG. 10D illustrates various BIM-battery configurations. The BIMs 100 may be connected to a respective battery or batteries (202) and stacked in parallel, in series, or a series / parallel combination. The BIMs 100 may be connected to a battery 202 having a BMS and / or a battery 202 lacking a BMS. A BIM 100 can be connected to multiple batteries 202, and the BIM 100 may be configured to perform smart power routing by selectively operating its core modules 150 to balance power delivery between the multiple batteries 202 coupled to a plurality of battery terminals. In some embodiments, the BIM 100 can be configured to change a series configuration or a parallel configuration of batteries 202 in software to reflect a desired series -connected topology, parallel-connected topology, or combination series-and-parallel topology.

[0098] As used herein, “battery 202” refers generally to a battery energy storage unit at any level of a battery hierarchy, including a battery cell, battery module, battery string, battery pack, or other assembly. Similarly, “BMS" as indicated in the figures refers generally to battery management electronics at any applicable level of the battery hierarchy, which may include cell interface boards or cell monitoring boards configured to monitor individual cell voltages and temperatures, string or stack controllers, master BMS boards, or combinations thereof. Cell-level monitoringelectronics are generally assumed to be present within the battery 202 to provide cell voltage and temperature data to the BIM 100, whether or not a higher-level BMS is explicitly shown in the figures. Each battery 202 illustrated in FIGS. 10B and 10C may represent a battery at any level of the battery hierarchy (e.g., a battery module, string, or pack), and the associated BMS may represent battery management electronics at the corresponding level. In some embodiments, the primary control circuit 116 is configured to perform master BMS functions, including overall pack health monitoring, cell balancing coordination, thermal management, and fault management, either in place of or in addition to a separate master BMS board associated with the battery 202. When a battery 202 includes an existing master BMS, the primary control circuit 116 may be configured to operate as a supervisory layer, communicating with the existing master BMS via the battery data terminal 103 while providing additional monitoring, control, and integration functions.

[0099] FIG. 10D further illustrates that, in addition to embodiments in which the BIM 100 integrates a battery, a generic integration module (GIM) 300a, 300b can be implemented as a general-purpose platform evolved from the BIM 100 for integrating other power sources and / or loads. In the illustrated example, the GIM 300a is coupled to a power source 216 (e.g., a supercapacitor bank, fuel cell system, renewable energy input, generator, or other DC power source) and can include a switching circuit and control circuit configured to provide a controllable electrical power path between the power source 216 and a system bus and to implement monitoring, protection, and isolation functions analogous to those described herein for the BIM 100. In the illustrated example, the GIM 300b is coupled to a load 218 (e.g., an electric motor drive, DC / DC converter, grid-tie inverter, or other power conversion equipment) and can be configured to selectively connect and disconnect the load 218 to and from the system bus, manage precharge and / or inrush current for the load 218, and provide fault isolation and status reporting. In some embodiments, the GIMs 300a, 300b communicate with one or more system-level controllers of the layered control system (e.g., PSC 220, system controller 210, and / or second tier controller 219) to coordinate power routing and operating modes across batteries 202, other power sources 216, and loads 218.

[0100] The BIM 100 and the GIM 300a, 300b are each members of a family of Universal Integration Modules (UIMs) that share a common core module architecture. The UIM family may further include specialized integration modules such as a motor integration module (MIM), a powerplant integration module (PPIM), a fuel cell integration module (FCIM), and a photovoltaic integration module (PVIM), each configured for integration with a respective power source or load type while sharing the modular core architecture, standardized enclosure design, and driver-based software framework described herein for the BIM 100. The GIM is a general-purpose UIM configurable for DC power sources or loads not served by a dedicated specialized integration module. SpecializedUIMs are described in related patent applications. In some embodiments, the BIM 100 and other UIMs are deployed together within a Universal Power System Integration Platform (UPSIP) wherein a power supervisory controller (PSC) coordinates operation across the UIM family.

[0101] The hybrid or electric power system can therefore include source and loads, an integration module (e.g., BIM, CdM, MIM, PPIM, FCIM, PVIM, or other UIM) coupled to a source or load. The integration module can include a source / load terminal configured to couple to voltage terminals the source / load, a system terminal configured to couple to voltage terminals of the hybrid or electric power system, a switching circuit providing a controllable electrical power path between the source / load terminal and the system terminal of the integration module and comprising multiple core modules each having a respective power stage circuit, a primary control circuit in electrical communication with the core modules and configured to provide a respective control signal to each respective core module to operate the respective power stage circuit, and a controller (e.g., PSC 220, PTC 210, variations thereof, or alternatives thereto as understood by a person skilled in the pertinent art informed by the disclosure herein) in communication with the primary control circuit of the integration module and configured to provide control parameters to the integration module. The controller of the hybrid or electric power system can include one or more processors and non-transitory computer-readable medium in communication with the one or more processors with instructions thereon configured to cause the controller to perform operations described herein.

[0102] In some embodiments, a BIM 100 connected to a plurality of battery terminals may include DC-DC conversion capability enabling the primary control circuit 116 to actively balance power delivery between batteries 202 connected to the plurality of battery terminals 102, in addition to selectively connecting and disconnecting individual batteries 202.

[0103] The system components illustrated in FIG. 10D and the modular design of the BIM 100 allow for a multitude of configurations of the BIM 100 for hybrid or electric power systems.

[0104] One embodiment includes a BIM development platform, a modular integration unit designed for engineering testbeds, hybrid-electric powertrain development benches, and lab environments where COTS battery modules need to be rapidly integrated and tested.

[0105] One embodiment includes a BIM for hybrid-electric aircraft, a flight-grade version of the BIM designed for integration into hybrid VTOL aircraft, cargo drones, and regional electric aircraft requiring robust fault protection, EMI filtering, and reconfigurable power delivery. The BIM may be certified for compliance with standards like SAE J- 1739, ARP5580, DO-311 A, DO-160, andTSO-C179b, suitable for type-certificated electric aircraft platforms under FAA or EASA regulations.One embodiment includes a BIM-integrated energy storage system (ESS), a packaged battery and BIM solution for stationary applications like microgrids, grid-tied solar systems, data centers, or emergency backup systems in telecom, commercial, or military installations.

[0106] One embodiment includes a BIM for mobile power units and vehicle power systems, which include drop-in BIMs for commercial electric or hybrid-electric vehicles (e.g., delivery vans, construction equipment, or electric trucks) to simplify battery-pack integration and enable multivendor battery sourcing.

[0107] One embodiment includes modular stackable BIM kits, which are configurable kits with stackable BIM core modules and enclosure options, allowing OEMs and developers to build scalable battery integration systems themselves from 25 kW to 1.5MW.

[0108] One embodiment includes a BIM for electric marine applications, which includes a sealed, corrosion-resistant BIM for electric and hybrid marine propulsion systems, including femes, tugboats, and autonomous underwater vehicles (AUVs).

[0109] One embodiment includes a BIM-enabled smart charging interface, a version of the BIM designed to act as an intelligent interface between EV chargers and swappable battery modules or storage systems, enabling flexible charge management.

[0110] One embodiment includes a BIM for military tactical platforms, which includes ruggedized BIM units for integration into military ground vehicles, UAVs, and mobile power generation units with advanced EMI resilience and fault containment capabilities.

[0111] One embodiment includes retrofit BIM solutions for legacy fleets, which includes adaptable BIM-based products for retrofitting older diesel- or gas-powered vehicles, boats, or aircraft with electric / hybrid drive systems.

[0112] One embodiment includes General Integration Module (GIM), a general-purpose platform evolved from the BIM that supports not just batteries, but also integration of supercapacitors, fuel cells, and renewable energy inputs in mobile and stationary systems.

[0113] One embodiment includes BIMs configured for power routing in distributed energy applications, which includes BIMs in decentralized microgrids, enabling autonomous reconfiguration and power routing across energy storage, renewables, and loads.

[0114] One embodiment includes space-qualified BIMs, which includes radiation-hardened and space-rated BIM modules for satellites, surface rovers, lunar landers, or deep-space power management systems requiring modular battery integration and fault isolation.

[0115] One embodiment includes a BIM for high-power rail electrification systems, which includes industrial-scale BIM variants supporting multi-megawatt energy storage and battery-smoothing systems in electrified freight and passenger rail networks.One embodiment includes consumer or light industrial portable energy systems, which include scaled-down BIM designs embedded in ragged battery units for field tools, backup generators, mobile workstations, or disaster response units.

Claims

CLAIMSWhat is claimed is:

1. A battery integration module (BIM), comprising:a battery terminal configured to couple to DC voltage terminals of a battery;a system terminal configured to couple to DC voltage terminals of a hybrid or electric power system;a switching circuit providing a controllable electrical power path between the battery terminal and the system terminal, the switching circuit comprising a plurality of core modules in the controllable electrical power path, each respective core module of the plurality of core modules comprising respective battery-side connectors, respective system-side connectors, and a respective power stage circuit between the respective battery-side connectors and the respective system-side connectors, the plurality of core modules being connected in a series, parallel, or combination series and parallel connection via the respective battery-side connectors and the respective system-side connectors such that each respective core module forms a respective controllable portion of the controllable electrical power path; anda primary control circuit in electrical communication with each of the plurality of core modules and configured to provide a respective control signal to each respective core module to operate the respective power stage circuit to thereby control the respective controllable portion of the controllable electrical power path.

2. The BIM of claim 1, wherein the respective power stage circuit of each of the plurality of core modules is controllable by the primary control circuit to connect and disconnect the respective battery-side connectors to and from the respective system-side connectors to thereby, by software control, selectively activate or deactivate individual core modules.

3. The BIM of claim 2,wherein the respective power stage circuit of each of the plurality of core modules comprises a high-side switch circuit and a low-side switch circuit each comprising at least one solid-state switch controllable in response to the respective control signal provided by the primary control circuit to connect and disconnect the respective battery-side connectors to and from the respective system-side connectors,wherein the high-side switch circuit is electrically between a positive battery-side connector of the respective battery-side connectors and a positive system-side connector of the respective system-side connectors, andwherein the low-side switch circuit is electrically between a negative battery-side connector of the respective battery-side connectors and a negative system-side connector of the respective system-side connectors.

4. The BIM of claim 2, wherein the primary control circuit is configured to selectively connect or disconnect the respective battery-side connectors from the respective system-side connectors of one or more core modules of the plurality of core modules based at least in part on an operating condition of the hybrid or electric power system.

5. The BIM of claim 2, wherein the primary control circuit is configured to isolate a faulted core module of the plurality of core modules by disconnecting the respective battery-side connectors of the faulted core module from the respective system-side connectors of the faulted core module, while continuing to operate one or more remaining core modules of the plurality of core modules to maintain power delivery through the controllable electrical power path at a reduced capacity.

6. The BIM of claim 1, wherein the respective power stage circuit of each of the plurality of core modules comprises a respective precharge circuit controllable by the primary control circuit.

7. The BIM of claim 1, wherein the respective power stage circuit of each of the plurality of core modules comprises a respective resistive braking branch configured to be turned on to dissipate excess power for battery protection.

8. The BIM of claim 1,wherein the respective power stage circuit of each of the plurality of core modules comprises at least one sensor comprising: a voltage sensor, a current sensor, a temperature sensor, or combination thereof,wherein each of the plurality of core modules comprises a core module control circuit configured to receive sensor measurements from the at least one sensor and control operation of the respective power stage circuit based at least in part on the sensor measurements.

9. The BIM of claim 1,wherein the respective power stage circuit of each of the plurality of core modules comprises at least one sensor comprising: a voltage sensor, a current sensor, a temperature sensor, or combination thereof,wherein each core module is configured to provide a fault signal to the primary control circuit in response to a fault condition measured by the at least one sensor, andwherein the primary control circuit is configured to control the respective power stage circuit based at least in part on the fault signal.

10. The BIM of claim 9,wherein the primary control circuit is configured to control operation of the switching circuit according to a state machine including at least a precharge state, an energized state, and a fault state (“states”), andwherein transitions between the states are based at least in part on data from the at least one sensor of at least one of the plurality of core modules.

11. The BIM of claim 1, wherein each of the plurality of core modules comprises a respective electromagnetic interference (EMI) filter circuit in series with the respective power stage circuit, the respective EMI filter circuit being configured to reduce electromagnetic noise between the respective system-side connectors and the respective battery-side connectors.

12. The BIM of claim 1,wherein the switching circuit comprises at least one relay, in the controllable electrical power path, between the battery terminal the plurality of core modules and / or between the system terminal and the plurality of core modules, andwherein the primary control circuit is configured to open the controllable electrical power path, thereby disconnecting the battery terminal from the system terminal by: (i) first, controlling the respective power stage circuit of each of the plurality of core modules to open the respective controllable portion of the controllable electrical power path , and (ii) next, opening the at least one relay.

13. The BIM of claim 12,wherein the respective power stage circuit of each of the plurality of core modules comprises one or more solid-state switches each controllable in response to the respective control signal provided by the primary control circuit to connect and disconnect the battery terminal to and from the system terminal, andwherein the primary control circuit is configured to open the one or more solid-state switches before opening the at least one relay.

14. The BIM of claim 12, wherein the at least one relay comprises a breaking capacity less than a maximum operating current of the controllable electrical power path.

15. The BIM of claim 1, comprising:a charging terminal configured to couple to a battery charging circuit,a charge relay between the switching circuit and the charging terminal, wherein the primary control circuit is configured to control operation of the charge relay based at least in part on a condition of the battery, a sensor measurement of the BIM, or combination thereof.

16. The BIM of claim 1 , comprising:an enclosure containing the switching circuit and the primary control circuit and comprising an electromagnetic shield separating the primary control circuit from the switching circuit.

17. The BIM of claim 1, comprising:an enclosure containing the switching circuit and the primary control circuit and comprising a plurality of slots each configured to receive a core module such that at least a portion of the plurality of slots are populated by the plurality of core modules.

18. The BIM of claim 17, wherein the plurality of core modules received in the plurality of slots are substantially identical and interchangeable with one another within the plurality of slots.

19. The BIM of claim 1, comprising:an enclosure containing the switching circuit and the primary control circuit, wherein the enclosure is configured to be user-modified to more than one series and parallel configurations of core modules.

20. The BIM of claim 19, wherein the enclosure comprises configurable conductive interconnections between exposed connectors of the plurality of core modules, the configurable conductive interconnections being arrangeable within the enclosure to determine a series, parallel, or combination series and parallel connection of one or more circuit branches of the plurality of core modules.

21. The BIM of claim 19, wherein the more than one series and parallel configurations of core modules are configured to provide a BIM having functionality across a range of voltage, current, or power ratings.

22. The BIM of claim 1, wherein the BIM is configured to be electrically coupled in parallel to one or more additional BIMs to provide a parallel battery connection to the hybrid or electric power system.

23. The BIM of claim 1, wherein the BIM is configured to be electrically coupled in series with one or more additional BIMs to provide a series battery connection to the hybrid or electric power system.

24. The BIM of claim 1, wherein the respective power stage circuit of each of the plurality of core modules comprises bus bars between the respective battery-side connectors and the respective system-side connectors.

25. The BIM of claim 24, wherein the plurality of core modules each comprise a respective printed circuit board (PCB) and the bus bars comprise one or more of: deep copper traces within the PCB, discrete conductive structures mechanically coupled to the PCB, or conductive layers embedded within a laminate of the PCB.

26. The BIM of claim 1, comprising:an enclosure containing the switching circuit and the primary control circuit, wherein the enclosure comprises an exterior shape configured to be mechanically stackable with one or more additional BIMs having a similar exterior shape.

27. The BIM of claim 1, wherein the plurality of core modules comprise a modular housing configured for mechanically stacking of one core module adjacent to another.

28. The BIM of claim 1, comprising:a control data terminal in electrical communication with the primary control circuit and configured to receive control parameters from an external device,wherein the external device comprises one or more of: a power supervisory controller of the hybrid or electric power system, a vehicle controller, a test stand controller, a computing device, or a charger controller,wherein the primary control circuit is configured to operate the plurality of core modules based at least in part on the control parameters.

29. The BIM of claim 28, wherein the external device comprises a computing device or controller configured to provide test parameters, calibration data, or diagnostic commands to the primary control circuit.

30. The BIM of claim 1, comprising:a battery data terminal in electrical communication with the primary control circuit and configured to couple with a data connector of the battery; anda control data terminal in electrical communication with the primary control circuit and configured to communicate with the hybrid or electric power system based at least in part on data received from the battery data terminal.

31. The BIM of claim 1, comprising:a battery data terminal in electrical communication with the primary control circuit and configured to couple with a data connector of the battery, wherein the primary control circuit is configured to operate the plurality of core modules based at least in part on data received from the battery data terminal.

32. The BIM of claim 31, comprising:a configuration data terminal in electrical communication with the primary control circuit and configured to couple with a computing device,wherein the primary control circuit is configured to receive a driver defining a battery management system (BMS) interface configuration, andwherein the primary control circuit is configured to communicate with the battery via the battery data terminal using the BMS interface configuration.

33. The BIM of claim 1, comprising:a configuration data terminal in electrical communication with the primary control circuit and configured to couple with a computing device,wherein the primary control circuit is configured to receive a driver including a battery-specific configuration of the battery, andwherein the primary control circuit is configured to operate the plurality of core modules based at least in part on the battery-specific configuration.

34. The BIM of claim 33,wherein the driver comprises operational parameters for the battery and is configured to provide sensor data from the battery to the primary control circuit, andwherein the primary control circuit is configured to provide control commands to a battery management system of the battery based at least in part on the driver.

35. The BIM of claim 33, wherein the battery-specific configuration comprises a precharge profile, a fault threshold, a timing configuration, or combination thereof.

36. The BIM of claim 1, comprising:a configuration data terminal in electrical communication with the primary control circuit and configured to couple with a computing device,wherein the primary control circuit is configured to receive customized fault response instructions, andwherein the primary control circuit, in response to a fault condition or anomalous operating condition detected by the primary control circuit, is configured to operate the switching circuit based at least in part on the customized fault response instructions.

37. The BIM of claim 1, wherein the hybrid or electric power system includes a flight vehicle, an automotive vehicle, a sea craft, a rail vehicle, stationary microgrids or energy storage systems, a renewable energy grid, industrial equipment, heavy equipment, grid infrastructure, defense vehicle, or combination thereof.

38. The BIM of claim 1, further comprising:a plurality of battery terminals including said battery terminal, each configured to couple to respective DC voltage terminals of a respective battery of a plurality of batteries,wherein the primary control circuit is configured to selectively operate the plurality of core modules to connect and disconnect individual ones of the plurality of batteries coupled to the plurality of battery terminals.

39. The BIM of claim 38, wherein the primary control circuit is configured to perform smart power routing by selectively operating the plurality of core modules to balance power delivery between the plurality of batteries coupled to the plurality of battery terminals.

40. The BIM of claim 38, wherein the primary control circuit is configured to perform smart power routing by selectively operating the plurality of core modules to change a series configuration or a parallel configuration of the plurality of batteries in software.

41. fhe BIM of claim 1, wherein the primary control circuit is configured to change a series configuration or a parallel configuration of the plurality of core modules in software to reflect a series-connected topology, a parallel-connected topology, or a combination series-and-parallel topology of the plurality of core modules.

42. A battery integration module (BIM) kit, comprising:a BIM enclosure, comprising:a battery terminal configured to couple to DC voltage terminals of a battery, a system terminal configured to couple to DC voltage terminals of a hybrid or electric power system,a plurality of core slots configured to be connected in a series, parallel, or combination series and parallel connection, anda primary control circuit comprising data connections to the plurality of core slots; anda plurality of core modules configured to be inserted in the plurality of core slots to provide at least a portion of a controllable electrical power path between the battery terminal and the system terminal and configured to be controlled by the primary control circuit via the data connections to the plurality of core slots.

43. The BIM kit of claim 42, wherein each core module of the plurality of core modules comprises a respective precharge circuit and a respective resistive braking branch, each controllable by the primary control circuit.

44. The BIM kit of claim 42,wherein each core module of the plurality of core modules comprises a respective electromagnetic interference (EMI) filter circuit in series with a respective power stage circuit, the respective EMI filter being configured to reduce electromagnetic noise between system-sideconnectors and battery-side connectors of a respective core module of the plurality of core modules, andwherein the BIM enclosure comprises at least one relay in the controllable electrical power path and the primary control circuit is configured to open the controllable electrical power path by: (i) first, controlling the respective power stage circuit of each of the plurality of core modules to open the respective controllable portion of the controllable electrical power path, and (ii) next, opening the at least one relay.

45. The BIM kit of claim 42, wherein the plurality of core slots are configurable to more than one series and parallel arrangements of the plurality of core modules, and the primary control circuit is configured to selectively activate or deactivate individual core modules by software control.

46. The BIM kit of claim 42,wherein the BIM enclosure comprises a configuration data terminal in electrical communication with the primary control circuit and configured to couple with a computing device,wherein the primary control circuit is configured to receive a driver defining a battery management system (BMS) interface configuration and to communicate with a battery via a battery data terminal using the BMS interface configuration, andwherein the primary control circuit is configured to receive a battery- specific configuration and to operate the plurality of core modules based at least in part on the batteryspecific configuration.

47. The BIM kit of claim 42,wherein the BIM enclosure comprises a configuration data terminal in electrical communication with the primary control circuit and configured to couple with a computing device, wherein the primary control circuit is configured to receive a customized fault response instruction, andwherein the primary control circuit, in response to a fault condition or anomalous operating condition, is configured to operate the plurality of core modules based at least in part on the customized fault response instruction.

48. A method of operating a battery integration module (BIM) in communication with a battery and a hybrid or electric power system, the BIM comprising a configuration data terminal, a primary control circuit, a switching circuit comprising a plurality of core modules each having a respective power stage circuit, and at least one relay, the method comprising:receiving, via the configuration data terminal, a driver defining a battery management system (BMS) interface configuration;receiving, via the configuration data terminal one or more of:a battery- specific configuration,operational parameters for the battery,a hybrid or electric power system-specific configuration, oroperational parameters for the hybrid or electric power system;communicating with the battery via a battery data terminal using the BMS interface configuration;operating the plurality of core modules based at least in part on the battery-specific configuration, operational parameters for the battery, a hybrid or electric power system-specific configuration, or operational parameters for the hybrid or electric power system;controlling the switching circuit according to a state machine comprising transitions between operating states based at least in part on sensor data from one or more of the plurality of core modules;disconnecting the battery from a system terminal by first opening a power stage circuit of the switching circuit of each of the plurality of core modules to reduce current through the at least one relay to substantially zero, and then opening the at least one relay; andin response to a fault condition or anomalous operating condition detected by the primary control circuit, operating the switching circuit based at least in part on a customized fault response instruction previously received via the configuration data terminal.

49. A hybrid or electric power system, comprising:a battery;a battery integration module (BIM) coupled to the battery, the BIM comprising:a battery terminal configured to couple to DC voltage terminals of the battery, a system terminal configured to couple to DC voltage terminals of the hybrid or electric power system,a switching circuit providing a controllable electrical power path between the battery terminal and the system terminal and comprising a plurality of core modules each having a respective power stage circuit, anda primary control circuit in electrical communication with each of the plurality of core modules and configured to provide a respective control signal to each respective core module to operate the respective power stage circuit; anda controller in communication with the primary control circuit of the BIM and configured to provide control parameters to the BTM.

50. The hybrid or electric power system of claim 49, wherein the controller comprises a power supervisory controller configured to coordinate power distribution, operational control, and diagnostic data exchange across the hybrid or electric power system.

51. The hybrid or electric power system of claim 49, comprising a plurality of BIMs, each coupled to a respective battery, wherein the controller is configured to communicate with the primary control circuit of each of the plurality of BIMs.

52. The hybrid or electric power system of claim 49, further comprising one or more universal integration modules (UIMs) each coupled to a respective power source or load, each UIM comprising a switching circuit comprising a plurality of core modules and a control circuit configured to communicate with the controller.

53. A core module for a battery integration module (BIM), the core module comprising:battery-side connectors comprising a positive battery-side connector and a negative batteryside connector configured to couple to a battery-side power path;system-side connectors comprising a positive system-side connector and a negative systemside connector configured to couple to a system-side power path;a power stage circuit between the battery-side connectors and the system-side connectors, the power stage circuit comprising a high-side switch circuit and a low-side switch circuit each comprising at least one solid-state switch; anda core module control circuit configured to generate drive signals for the at least one solid-state switch of the high-side switch circuit and the low-side switch circuit and to autonomously detect and respond to fault conditions based at least in part on sensor measurements within the core module;wherein the core module is configured to provide:software-controlled isolation of the battery-side power path from the system-side power path by opening the at least one solid-state switch,precharge of a downstream bus by selectively operating the power stage circuit through a precharge circuit, andfault response by opening the at least one solid-state switch in response to a fault condition detected by the core module control circuit.

54. The core module of claim 53, wherein the core module comprises a standardized form factor configured for insertion into a slot of a BIM enclosure and for electrical connection inseries, parallel, or combination series and parallel with one or more additional core modules via the battery-side connectors and system-side connectors.

55. The core module of claim 53, further comprising a resistive braking branch configured to be selectively activated to dissipate excess power for battery or system protection.

56. The core module of claim 53, further comprising an electromagnetic interference (EMI) filter circuit in series with the power stage circuit, configured to reduce electromagnetic noise between the system-side connectors and the battery-side connectors.

57. A battery integration module (BIM) enclosure, comprising:a battery terminal configured to couple to DC voltage terminals of a battery;a system terminal configured to couple to DC voltage terminals of a hybrid or electric power system;a plurality of core slots configured to receive a plurality of core modules, the plurality of core slots comprising battery-side slot connectors and system-side slot connectors arranged to connect received core modules in a series, parallel, or combination series and parallel connection to form at least a portion of a controllable electrical power path between the battery terminal and the system terminal;a primary control circuit comprising data connections to each of the plurality of core slots, the primary control circuit configured to provide respective control signals to core modules received in the plurality of core slots;an electromagnetic shield separating the primary control circuit from the plurality of core slots; andat least one relay in the controllable electrical power path between the battery terminal and the plurality of core slots and / or between the system terminal and the plurality of core slots.

58. A battery integration module (BIM), comprising:a battery terminal configured to couple to DC voltage terminals of a battery;a system terminal configured to couple to DC voltage terminals of a hybrid or electric power system;a switching circuit providing a controllable electrical power path between the battery terminal and the system terminal;a primary control circuit configured to control the switching circuit; anda configuration data terminal in electrical communication with the primary control circuit and configured to couple with a computing device,wherein the primary control circuit implements a driver-based abstraction layer configured to receive, via the configuration data terminal, a driver for a batterymanagement system (BMS) associated with the battery, the driver defining a BMS interface configuration for communicating with the BMS via a battery data terminal, and wherein the primary control circuit is configured to communicate with the BMS using the BMS interface configuration such that the BIM is operable with different third- party battery types by loading a corresponding driver for each battery type without modification of firmware of the primary control circuit.

59. The BIM of claim 58, wherein the driver further defines a battery-specific configuration comprising operational parameters for the battery, and the primary control circuit is configured to operate the switching circuit based at least in part on the battery-specific configuration.

60. The BIM of claim 58, wherein the primary control circuit is configured to receive, via the configuration data terminal, a customized fault response instruction, and in response to a fault condition or anomalous operating condition, operate the switching circuit based at least in part on the customized fault response instruction.

61. A battery integration module (BIM), comprising:a battery terminal configured to couple to DC voltage terminals of a battery;a system terminal configured to couple to DC voltage terminals of a hybrid or electric power system;a switching circuit providing a controllable electrical power path between the battery terminal and the system terminal;a primary control circuit configured to control the switching circuit;a configuration data terminal in electrical communication with the primary control circuit and configured to couple with a computing device; anda non-transitory computer-readable medium in communication with the primary control circuit and storing a configurable operational profile received via the configuration data terminal, the configurable operational profile defining:one or more state machine configurations comprising a plurality of operating states and transition conditions between the plurality of operating states, the transition conditions based at least in part on sensor data, battery data, system commands, or combinations thereof, anda fault response configuration comprising a plurality of fault conditions and a respective predetermined response action for each of the plurality of fault conditions, wherein the primary control circuit is configured to control the switching circuit in accordance with the one or more state machine configurations and to execute therespective predetermined response action upon detection of a corresponding fault condition, andwherein the configurable operational profile is replaceable via the configuration data terminal to adapt the BIM to different applications without modification of firmware of the primary control circuit.

62. The BIM of claim 61 , wherein the plurality of fault conditions comprise one or more of: loss of communication with an external controller, degraded communication, sensor fault, overcurrent, overvoltage, undervoltage, overtemperature, or battery management system fault.

63. The BIM of claim 61, wherein the respective predetermined response actions comprise one or more of: opening the controllable electrical power path, activating a resistive braking branch, transitioning to a degraded operating mode, maintaining a current operating state, or executing a controlled shutdown sequence.

64. The BIM of claim 61, wherein the switching circuit comprises a plurality of core modules each comprising a respective power stage circuit, the plurality of core modules being connected in a series, parallel, or combination series and parallel connection, and the primary control circuit is configured to provide a respective control signal to each core module to operate the respective power stage circuit in accordance with the configurable operational profile.

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