JPWO2021211630A5 - - Google Patents

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of and priority to U.S. Provisional Application No. 63/009,996, filed April 14, 2020, U.S. Provisional Application No. 63/043,731, filed June 24, 2020, U.S. Provisional Application No. 63/069,369, filed August 24, 2020, and U.S. Provisional Application No. 63/084,300, filed September 28, 2020, all of which are incorporated by reference herein in their entirety and for all purposes.

The subject matter described herein generally relates to systems, devices, and methods for charging and discharging modular-based cascaded energy systems that can be used in mobile and stationary applications.

Energy systems with multiple energy sources or sinks are common in many industries. One example is the automotive industry. Today's automotive technology, as developed over the past century, is characterized by the interplay of motors, mechanical elements, and electronics, among others. These are the main components that affect vehicle performance or driver experience. Motors are of combustion and electric type, and in almost all cases, the rotational energy from the motor is delivered through a set of highly sophisticated mechanical elements such as clutches, transmissions, differentials, drive shafts, torque tubes, couplers, etc. These parts largely control the torque transformation and distribution to the wheels and define the performance and drivability of the car.

Electric vehicles (EVs) include various electrical systems associated with the drive train, including battery packs, chargers, and motor controls, among others. High-voltage battery packs are typically organized into a serial chain of low-voltage battery modules. Each such module further includes a set of individual cells connected in series and a simple built-in battery management system (BMS) to regulate basic battery-related characteristics such as state of charge and voltage. Electronics with more sophisticated capabilities or some form of high-performance interconnectivity are lacking. As a result, any monitoring or control functions, even if present elsewhere in the vehicle, are handled by separate systems that lack the ability to monitor individual battery health, state of charge, temperature, and other performance-affecting metrics. Also, there is no ability to meaningfully regulate any form of power draw per individual battery. Some of the major consequences are: (1) the weakest cell limits the overall performance of the entire battery pack; (2) failure of any cell or module leads to the need to replace the entire pack; (3) battery reliability and safety are significantly reduced; (4) battery life is limited; (5) thermal management is difficult; (6) the battery pack always operates below its maximum capacity; and (7) the sudden inrush of power from regenerative braking cannot be easily stored in the battery and requires dissipation through a dump resistor.

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

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

Many of these deficiencies apply to a significant extent not only to automobiles, but also to other motor-driven vehicles, as well as to stationary applications. For these and other reasons, a need exists for improved systems, devices, and methods for energy systems for mobile and stationary applications.

Exemplary embodiments of systems, devices, and methods are provided herein for charging and discharging an energy system having multiple modules arranged in a cascaded manner to generate and store power. Each module can include an energy source and a switch network that selectively couples the energy source to other modules in the system to generate power or to receive and store power from a charging source. The energy system can be arranged in a single-phase or multi-phase topology with multiple series or interconnected arrays. The energy system can be arranged with multiple subsystems to provide power to one or more motors. The embodiments can be charged using a multi-phase AC charging signal, a single-phase AC charging signal, and/or a DC charging signal.

The modules can output status information to a control system that can use the status information to charge the modules while maintaining or targeting an equilibrium condition across one or more operating characteristics of the modules, such as state of charge and/or temperature. The control system can also control charging in a manner that limits displacements and distortions in the system. In some embodiments, charging occurs while bypassing the load or motor, while in other embodiments, charging occurs through the load or motor. Charging through the motor can be implemented in a manner that offsets the component fluxes of the motor.

Embodiments can have numerous topologies, including single phase, multi-phase (e.g., three-phase and six-phase), topologies with linear arrays or arrays in delta and series configurations, topologies with multiple loads and voltage requirements, and topologies with one or more interconnection modules to perform array-to-array or phase-to-phase balancing and/or to provide power to one or more auxiliary loads, to name a few. Also provided are embodiments that implement a modular energy system within a charging source to perform multi-phase, single-phase AC, or DC charging of electric vehicles.

Exemplary embodiments are also provided for multiple subsystem configurations, where each subsystem can provide a different voltage and/or utilize a different type of energy source. Exemplary embodiments are provided for installation of modules of an energy system within the interior space of an EV chassis. Exemplary embodiments are further provided for powering an automated suspension and/or steering system, including additional embodiments of modules and topologies therefor.

Other systems, devices, methods, features, and advantages of the subject matter described herein will be, or become, apparent to one with skill in the art upon examination of the following figures and detailed description. All such additional systems, methods, features, and advantages are intended to be included within this description, be within the scope of the subject matter described herein, and be protected by the accompanying claims. Features of the example embodiments should not be construed as limiting the appended claims in any way absent an express recitation of those features in the claims.
The present invention provides, for example, the following:
(Item 1)
1. A modular energy system controllable to supply electrical power to a load, comprising:
three arrays, each array comprising at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
a charging port configured to conduct a DC or single phase AC charging signal;
a routing circuitry connected between the charging port and the three arrays, the routing circuitry being controllable to selectively route the DC or single phase AC charging signal to each of the three arrays; and
A system comprising:
(Item 2)
13. The system of claim 1, further comprising a control system communicatively coupled to the routing circuitry, the control system configured to control the routing circuitry to selectively route the DC or single-phase AC charging signal to each of the three arrays.
(Item 3)
3. The system of claim 2, wherein the control system is communicatively coupled to each module of the three arrays and configured to control the converter of each module and charge each module.
(Item 4)
4. The system of claim 3, wherein the control system is configured to control the converter of each module according to a pulse width modulation or hysteresis technique.
(Item 5)
4. The system of claim 3, wherein each module comprises a monitor circuit configured to monitor status information of the module, each module is configured to output the status information to the control system, and the control system is configured to control the converter of each module based on the status information.
(Item 6)
6. The system of claim 5, wherein the status information relates to temperature and charge state of the modules, and the control system is configured to control the converter of each module to balance the temperature and charge state of all modules in the array.
(Item 7)
3. The system of claim 2, wherein the routing circuitry comprises a plurality of unidirectional solid-state repeaters controllable by the control system to selectively route the DC charging signal to each of the three arrays.
(Item 8)
8. The system of claim 7, wherein the unidirectional solid state repeater is a thyristor.
(Item 9)
the routing circuitry comprising a first port coupled to a DC+ line, a second port coupled to a DC- line, a third port coupled to the first array, a fourth port coupled to the second array, and a fifth port coupled to the third array; and
a first thyristor coupled between the first port and the third port;
a second thyristor coupled between the first port and the fourth port;
a third thyristor coupled between the fourth port and the second port;
a fourth thyristor coupled between the fifth port and the second port;
Equipped with
3. The system of claim 2, wherein the thyristor is controllable by the control system to selectively route the DC charging signal at the first port to either the third or fourth port and to selectively route signals at the fourth or fifth ports to the second port.
(Item 10)
the routing circuitry comprising a sixth port coupled to a first AC line and a seventh port coupled to a second AC line; and
a first diode coupled between the seventh port and the first and second thyristors;
a second diode coupled between the sixth port and the first and second thyristors;
a third diode coupled from the third and fourth thyristors to the sixth port;
a fourth diode coupled from the third and fourth thyristors to the seventh port; and
10. The system according to claim 9, comprising:
(Item 11)
3. The system of claim 2, wherein the routing circuitry comprises a plurality of bidirectional solid-state repeaters controllable by the control system to selectively route the DC or single-phase AC charging signal to each of the three arrays.
(Item 12)
12. The system of claim 11, wherein the bidirectional solid-state repeater is a triac.
(Item 13)
the routing circuitry comprises a first port configured to couple to a DC+ charging signal or a single phase AC line charging signal, a second port configured to couple to a DC- charging signal or a single phase AC neutral signal, a third port coupled to the first array, a fourth port coupled to the second array, and a fifth port coupled to the third array; and
a first triac coupled between the first port and the third port;
a second triac coupled between the first port and the fourth port;
a third triac coupled between the fourth port and the second port;
a fourth triac coupled between the fifth port and the second port;
3. The system according to claim 2, comprising:
(Item 14)
the triac is controllable by the control system to selectively route the DC charging signal at the first port to either the third or fourth port and to selectively route the signal at the fourth or fifth port to the second port when operating in a DC charging state;
the triac is controllable by the control system to selectively route the AC line charging signal at the first port to either the third or fourth port and to selectively route the signal at the fourth or fifth port to the second port during operation in a positive single phase AC charging condition, and to selectively route the signal at the second port to either the fourth or fifth port and to selectively route the signal at the third or fourth port to the first port during operation in a negative single phase AC charging condition;
Item 14. The system described in item 13.
(Item 15)
3. The system of claim 2, wherein the charging port is configured to conduct a three-phase AC charging signal, and the routing circuitry comprises a plurality of bidirectional solid-state repeaters controllable by the control system to selectively route the DC or single-phase AC charging signal to each of the three arrays.
(Item 16)
20. The system of claim 15, wherein the plurality of bidirectional solid-state repeaters comprise triacs.
(Item 17)
The routing circuitry comprises a first port configured to receive a DC or AC charging signal, a second port configured to receive an AC charging signal, and a third port configured to receive a DC or AC charging signal; and
a first triac coupled between the first port and a first line connectable to a first of the three arrays;
a second triac coupled between the second port and a second line connectable to a second of the three arrays;
a third triac coupled between the third port and a third line connectable to a third of the three arrays;
a fourth triac coupled between the first line and the second line;
a fifth triac coupled between the second line and the third line;
Item 16. The system according to item 15, comprising:
(Item 18)
18. The system of any of items 7-17, further configured to selectively disconnect all of the modules and the motor from the charging source.
(Item 19)
19. The system of any of items 1-18, wherein the three arrays are interconnected by at least one interconnection module.
(Item 20)
20. The system of claim 19, wherein the control system is configured to control the at least one interconnect module to supply voltage for at least one auxiliary load when the system is in a charging state.
(Item 21)
19. The system of any of items 1-18, wherein the three arrays are interconnected in a delta series configuration.
(Item 22)
19. The system of any of items 1-18, wherein the load is a six-phase load, the three arrays are a first set of arrays, and the system further comprises a second set of arrays comprising an additional three arrays of modules, and the system is configured to charge the first and second sets of arrays in parallel.
(Item 23)
15. The system of any of items 1-14, wherein the charging port is a first charging port, and the system further comprises a second charging port configured to receive a three-phase charging signal.
(Item 24)
24. The system of claim 23, wherein the first and second charging ports are integrated within a same user-accessible location.
(Item 25)
24. The system of claim 23, wherein the routing circuitry is connected to a line from the second charging port.
(Item 26)
26. The system of any of items 1-25, comprising a plurality of switches coupled between a first module of each array and the load, the plurality of switches being controllable to disconnect the load from the three arrays.
(Item 27)
The three arrays are of a first subsystem of the system configured to provide three-phase power to a first load, the system further comprising a second subsystem configured to provide three-phase power to a second load, the second subsystem comprising three arrays, each of the three arrays comprising at least two modules, the at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules of the second subsystem comprising an energy source and a converter;
the first and second subsystems are coupled together by a first plurality of switches such that the first and second subsystems are electrically connectable in parallel for charging;
27. The system according to any one of items 1-26.
(Item 28)
a third subsystem configured to provide three-phase power to a third load, the third subsystem comprising three arrays, each of the three arrays comprising at least two modules, the at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules of the third subsystem comprising an energy source and a converter;
the first and third subsystems are coupled together by a second plurality of switches such that the first and third subsystems are electrically connectable in parallel for charging;
28. The system according to item 27.
(Item 29)
29. A method of charging a modular energy system configured according to any of items 1-28, comprising:
controlling the modular energy system while a charging signal is applied to charge the modular energy system and balance at least one operating characteristic of the system.
A method comprising:
(Item 30)
30. The method of claim 29, wherein the at least one operating characteristic is temperature.
(Item 31)
30. The method of claim 29, wherein the charging signal is a three-phase charging signal, a single-phase charging signal, or a direct current (DC) charging signal.
(Item 32)
30. The method of claim 29, wherein the modular energy system is controlled to maintain a power factor of the system within a threshold of unity.
(Item 33)
30. The method of claim 29, wherein controlling the modular energy system includes controlling a converter of a module of the energy system.
(Item 34)
29. A control system for a modular energy system configured according to any of items 1-28.
(Item 35)
A computer-readable medium comprising a plurality of instructions that, when executed by processing circuitry, cause the processing circuitry to control charging for a modular energy system configured according to any of items 1-28.
(Item 36)
1. A modular energy system for an electric vehicle (EV), comprising:
a first subsystem configured to supply power to a first motor of the EV, the first subsystem comprising three arrays, each of the three arrays comprising at least two first modules, the at least two first modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two first modules, each of the first modules comprising an energy source and a converter;
a second subsystem configured to supply power to a second motor of the EV, the second subsystem comprising three arrays, each of the three arrays comprising at least two second modules, the at least two second modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two second modules, each of the second modules comprising an energy source and a converter;
a plurality of switches configured to selectively connect the first and second subsystems for charging;
Equipped with
A system, wherein a nominal output voltage of the first subsystem is greater than a nominal output voltage of the second subsystem.
(Item 37)
37. The system of claim 36, wherein each array of the first subsystem comprises more modules than each array of the second subsystem.
(Item 38)
Item 37. The system of item 36, wherein a nominal voltage of each first module is greater than a nominal voltage of each second module.
(Item 39)
37. The system of claim 36, wherein the energy source of each first module is a first type of battery and the energy source of each second module is a second type of battery, the first type being different from the second type.
(Item 40)
40. The system of claim 39, wherein the first type has a relatively greater energy density than the second type.
(Item 41)
41. The system of claim 40, wherein the second type has a relatively larger C-rate than the first type.
(Item 42)
42. The system of any of items 36-41, wherein the plurality of switches are configured to connect a first array of the first subsystem to a first array of the second subsystem in parallel, a second array of the first subsystem to a second array of the second subsystem in parallel, and a third array of the first subsystem to a third array of the second subsystem in parallel.
(Item 43)
a charging port configured to conduct a DC or single phase AC charging signal;
a routing circuitry connected between the charging port and the subsystem, the routing circuitry being controllable to selectively route the DC or single-phase AC charging signal to each parallel connection of an array of subsystems;
Item 43. The system of item 42, further comprising:
(Item 44)
44. The system of claim 43, further comprising a control system communicatively coupled to the routing circuitry and the plurality of switches, the control system configured to control selective routing of the routing circuitry.
(Item 45)
45. The system of claim 44, wherein the control system is communicatively coupled to the converter of each first module and each second module and configured to control the converter and charge each first and second module.
(Item 46)
46. The system of any of items 36-45, further comprising a third subsystem configured to supply power to a third motor of the EV, the third subsystem comprising three arrays, each of the three arrays comprising at least two third modules, the at least two third modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two third modules, each of the third modules comprising an energy source and a converter.
(Item 47)
47. The system of claim 46, wherein the plurality of switches is a first plurality of switches, the system further comprising a second plurality of switches configured to selectively connect the second and third subsystems for charging.
(Item 48)
48. The system of claim 47, wherein a maximum output voltage of the first subsystem exceeds a maximum output voltage of the third subsystem.
(Item 49)
48. The system of claim 47, wherein the first motor is configured to power rear wheels of the EV, the second motor is configured to power a first front wheel of the EV, and the third motor is configured to power a second front wheel of the EV.
(Item 50)
47. The system of claim 46, further comprising a fourth subsystem configured to supply power to a fourth motor of the EV, the fourth subsystem comprising three arrays, each of the three arrays comprising at least two fourth modules, the at least two fourth modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two fourth modules, each of the fourth modules comprising an energy source and a converter.
(Item 51)
The system of any of items 36-50, wherein the nominal output voltage of the first subsystem is a nominal peak line-to-line output voltage of the first subsystem, and the nominal output voltage of the second subsystem is a nominal peak line-to-line output voltage of the second subsystem.
(Item 52)
1. A modular energy system controllable to supply electrical power to a closed winding motor, comprising:
three arrays, each array comprising at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
a charging connector having a first port and a second port and configured to conduct a DC or single phase AC charging signal;
Equipped with
a first charge path extends from the first port, through first and second windings of the motor, through a first array, and terminates at the second port;
a second charge path extends from the first port, through the first winding and a third winding of the motor, through a second array, and terminates at the second port;
a third charging path extends from the first port of the connector, bypasses the motor, passes through a third array, and terminates at the second port.
(Item 53)
53. The system of claim 52, further comprising a control system communicatively coupled to the modules of the three arrays, the control system configured to control the converter of each module and charge each module.
(Item 54)
54. The system of claim 53, wherein the control system is configured to charge each of the three arrays in parallel with the DC charging signal.
(Item 55)
54. The system of claim 53, wherein the control system is configured to charge two of the three arrays in parallel with the DC charging signal.
(Item 56)
54. The system of claim 53, wherein the control system is configured to charge each of the three arrays in sequence with the DC charging signal.
(Item 57)
54. The system of claim 53, wherein the control system is configured to charge each of the three arrays in parallel with the single phase AC charging signal.
(Item 58)
54. The system of claim 53, wherein the control system is configured to charge two of the three arrays in parallel with the single-phase AC charging signal.
(Item 59)
54. The system of claim 53, wherein the control system is configured to charge each of the three arrays in sequence with the single-phase AC charging signal.
(Item 60)
54. The system of claim 53, wherein the control system is configured to charge in parallel along the first charging path and the second charging path such that flux generated on the first, second, and third windings of the motor is neutralized.
(Item 61)
54. The system of claim 53, further comprising a three-phase charging connector connected to a plurality of switches, the switches being controllable by the control system to selectively connect the three-phase charging connector to the three arrays.
(Item 62)
54. The system of claim 53, wherein the control system is configured to control the converter of each module according to a pulse width modulation or hysteresis technique.
(Item 63)
63. The system of claim 62, wherein each module comprises a monitor circuit configured to monitor status information of the module, each module is configured to output the status information to the control system, and the control system is configured to control the converter of each module based on the status information.
(Item 64)
64. The system of claim 63, wherein the status information relates to temperature and charge state of the modules, and the control system is configured to control the converter of each module to balance the temperature and charge state of all modules in the array.
(Item 65)
65. The system of any of items 52-64, wherein the three arrays are interconnected by at least one interconnection module.
(Item 66)
66. The system of claim 65, wherein the control system is configured to control the at least one interconnect module to supply voltage for at least one auxiliary load when the system is in a charging state.
(Item 67)
1. A charging source configured to charge an electric vehicle (EV), comprising:
1. A charging source comprising: a modular energy system comprising three arrays configured to generate electrical power in at least three phases, each array comprising at least two modules, the at least two modules being electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter.
(Item 68)
70. The charging source of claim 67, wherein the charging source is configured to connect to an external power supply and charge the energy source of the modular energy system.
(Item 69)
70. The charging source of claim 68, wherein the external power source is a power grid or a renewable energy source.
(Item 70)
70. The charging source of claim 68, wherein the charging source is configured to charge the EV at a first rate, and the charging source is configured to be charged by the external power source at a second rate, the first rate being greater than the second rate.
(Item 71)
monitor circuitry configured to detect harmonics available to the external power supply;
a control system configured to control the converter of the module to generate a compensation current to cancel the harmonics;
70. The charging source of claim 68, comprising:
(Item 72)
72. The charging source of claim 71, further comprising a DC/AC converter comprising a plurality of diodes for rectification.
(Item 73)
70. The charging source of claim 67, configured to charge the EV with a DC charging signal, a single-phase AC charging signal, or a three-phase AC charging signal.
(Item 74)
The EV includes a battery pack, the battery pack comprising:
Item 68. The charging source of item 67, comprising a modular energy system comprising three arrays configured to generate power in at least three phases, each array comprising at least two modules, the at least two modules being electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter.
(Item 75)
1. A modular energy system controllable to supply power to an open winding motor, comprising:
a first subsystem comprising three arrays, each array comprising at least two modules, the at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of an output voltage from each of the at least two modules, each of the modules comprising an energy source and a converter, the first subsystem being connected to a three-phase charging connector;
a second subsystem comprising three arrays, each array comprising at least two modules, the at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
Equipped with
the first and second subsystems are configured to connect to the motor such that a first winding of the motor is connected between a first array of the first subsystem and a first array of the second subsystem, a second winding of the motor is connected between a second array of the first subsystem and a second array of the second subsystem, and a third winding of the motor is connected between a third array of the first subsystem and a third array of the second subsystem.
(Item 76)
a first port of the three phase charging connector coupled to the first array of the first subsystem, a second port of the three phase charging connector coupled to the second array of the first subsystem, and a third port of the three phase charging connector coupled to the third array of the first subsystem, the system further comprising:
a first switch coupled between the first port and the second port;
a second switch coupled between the second port and the third port;
a DC or single phase AC charging connector coupled to the third port and to the third array of the second subsystem; and
Item 76. The system of item 75, comprising:
(Item 77)
1. A modular energy system for an electric vehicle (EV), comprising:
Three arrays, each array comprising at least two modules, the at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter.
Equipped with
the three arrays are configured to provide three-phase power for a first electric motor configured to provide motive power for at least one wheel of the EV;
The system, wherein at least one module of the three arrays is configured to provide power to a second electric motor of an electric suspension or electric steering mechanism of the EV.
(Item 78)
Item 78. The system of item 77, configured to provide power for two second electric motors of the EV.
(Item 79)
Item 78. The system of item 77, configured to provide power for four second electric motors of the EV.
(Item 80)
80. The system of claim 77, wherein the at least one module is the module of the three arrays closest to the second electric motor.
(Item 81)
80. The system of claim 77, wherein the at least one module is configured as an interconnect module coupled to at least two of the three arrays.
(Item 82)
80. The system of claim 77, comprising a plurality of interconnection modules coupled between the three arrays, each interconnection module comprising an energy source and a converter, the energy sources of the interconnection modules being connected in parallel.
(Item 83)
83. The system of claim 82, wherein the at least one module is one of the plurality of interconnected modules.
(Item 84)
84. The system of any of claims 77-83, further comprising an isolated converter, and wherein the at least one module of the three arrays is configured to provide power to the second electric motor using the isolated converter.
(Item 85)
84. The system of any of items 77-83, wherein the converter of the at least one module is a first converter, the at least one module comprises an isolated converter coupled to the energy source of the at least one module, and the at least one module is configured to provide power from the energy source, through the isolated converter, to the second electric motor.
(Item 86)
The isolated converter comprises:
a first DC/AC converter coupled to the energy source of the at least one module;
a transformer coupled to the DC/AC converter;
a second DC/AC converter coupled to the transformer;
Item 86. The system of item 85, comprising:
(Item 87)
87. The system of any of claims 77-86, wherein the second electric motor is an electric actuator.
(Item 88)
88. The system of any of items 77-87, wherein the second electric motor is part of an electric suspension of the EV.
(Item 89)
The system of any of items 77-87, wherein the second electric motor is part of an electric steering mechanism of the EV.
(Item 90)
90. The system of any of claims 77-89, wherein the three arrays are of a first subsystem of the system, the system further comprising at least one additional subsystem configured to provide three-phase power for a third electric motor of the EV configured to provide motive power for at least one wheel of the EV, the at least one additional subsystem comprising at least one additional module configured to provide power to a fourth electric motor of an electric suspension or electric steering mechanism of the EV.
(Item 91)
1. A modular energy system for an electric vehicle (EV), comprising:
Three arrays, each array comprising at least two stages of modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter.
Equipped with
a chassis of the electric vehicle having a first axis and a second axis perpendicular to a horizontal plane of the electric vehicle, a first dimension of the chassis along the first axis being relatively longer than a second dimension of the chassis along the second axis;
the three arrays are arranged in a puck configured to fit within the chassis;
each module of the three arrays has a first dimension aligned along the first axis and a second dimension aligned along the second axis, the second dimension of each module being relatively larger than the first dimension.
(Item 92)
Item 92. The system of item 91, wherein for each array, a majority of the modules of the array are aligned along the first axis.
(Item 93)
Item 93. The system of item 92, wherein a first tier of the array is arranged in an alternating manner at a first end of the pack.
(Item 94)
Item 94. The system of item 93, wherein the other stage of the array is aligned along the second axis.
(Item 95)
95. The system of any of claims 93-94, further comprising three interconnection modules arranged in an alternating manner at a second end of the pack.
(Item 96)
96. The system of any of claims 91-95, configured to provide three-phase power to a motor located adjacent the first end of the pack.
(Item 97)
92. The system of claim 91, wherein the three arrays are of a first subsystem, the system further comprising a second subsystem comprising three arrays of modules arranged in a symmetrical opposed manner relative to the first subsystem.
(Item 98)
Item 98. The system of item 97, further comprising three interconnection modules positioned between the first subsystem and the second subsystem and aligned along the second axis.
(Item 99)
1. A modular energy system for an electric vehicle (EV), comprising:
a first subsystem comprising three arrays configured to provide three-phase power to a first motor of the EV, each array comprising at least two stages of modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
a second subsystem comprising three arrays configured to provide three-phase power to a second motor of the EV, each array comprising at least two stages of modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
Equipped with
a chassis of the electric vehicle having a first axis and a second axis perpendicular to a horizontal plane of the electric vehicle, a first dimension of the chassis along the first axis being relatively longer than a second dimension of the chassis along the second axis;
the two subsystems are arranged in a pack configured to fit within the chassis;
each module of the two subsystems has a first dimension aligned along the first axis and a second dimension aligned along the second axis, the second dimension of each module being relatively smaller than the first dimension.
(Item 100)
100. The system of claim 99, wherein for each array, a majority of the modules of the array are aligned along the first axis.
(Item 101)
Item 101. The system of item 100, wherein each stage of the array is aligned along the second axis.
(Item 102)
102. The system of any of claims 99-101, further comprising three interconnection modules arranged in an alternating manner at a first end of the pack.
(Item 103)
103. The system of any of claims 99-102, wherein the first and second subsystems are configured to output power for the first and second motors at a second end of the pack.
(Item 104)
1. A modular energy system for an electric vehicle (EV), comprising:
a first subsystem comprising three arrays configured to provide three-phase power to a first motor of the EV, each array comprising at least two stages of modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
a second subsystem comprising three arrays configured to provide three-phase power to a second motor of the EV, each array comprising at least two stages of modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
a third subsystem comprising three arrays configured to provide three-phase power to a third motor of the EV, each array comprising at least two stages of modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
Equipped with
a chassis of the electric vehicle having a first axis and a second axis perpendicular to a horizontal plane of the electric vehicle, a first dimension of the chassis along the first axis being relatively longer than a second dimension of the chassis along the second axis;
the three subsystems are arranged in a pack configured to fit within the chassis;
each module of the first and second subsystems has a first dimension aligned along the first axis and a second dimension aligned along the second axis, the second dimension of each module being relatively smaller than the first dimension.
(Item 105)
Item 105. The system of item 104, wherein each module of the third subsystem has a first dimension aligned along the first axis and a second dimension aligned along the second axis, the second dimension of each module being relatively larger than the first dimension.
(Item 106)
Item 105. The system of item 104, wherein the first subsystem is positioned on a left side of the EV and the second subsystem is positioned on a right side of the EV.
(Item 107)
Item 107. The system of item 106, wherein the third subsystem is behind the first and second subsystems.
(Item 108)
Item 108. The system of item 107, wherein the first subsystem is configured to power a first motor for a front left wheel of the EV, the second subsystem is configured to power a second motor for a front right wheel of the EV, and the third subsystem is configured to power a third motor for a rear wheel of the EV.
(Item 109)
The system of any of claims 104-108, further comprising a plurality of interconnection modules positioned between the first subsystem and the second subsystem.
(Item 110)
110. The system of any of items 104-109, wherein each array of the first and second subsystems is aligned along the second axis.
(Item 111)
111. The system of any of claims 104-110, wherein the stages of each module of the first and second subsystems are aligned along the first axis.
(Item 112)
12. The system of any of claims 104-111, wherein a majority of the modules of each array of subsystems of the third subsystem are aligned along the first axis.
(Item 113)
The system of any of claims 104-112, wherein a majority of the stages of modules of the third subsystem are aligned along the second axis.
(Item 114)
Item 114. The system of item 113, wherein the first stage of modules of the third subsystem are arranged in an alternating manner.
(Item 115)
1. A modular energy system for an electric vehicle (EV), comprising:
four subsystems configured to provide three-phase power to four motors of the EV, each subsystem comprising three arrays, each array comprising a stage of at least two modules, the stages of at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
a chassis of the electric vehicle having a first axis and a second axis perpendicular to a horizontal plane of the electric vehicle, a first dimension of the chassis along the first axis being relatively longer than a second dimension of the chassis along the second axis;
the four subsystems are arranged in a pack configured to fit within the chassis;
each module of the first and second subsystems has a first dimension aligned along the first axis and a second dimension aligned along the second axis, the second dimension of each module being relatively smaller than the first dimension.
(Item 116)
Item 116. The system of item 115, further comprising a plurality of interconnection modules aligned along the first axis.
(Item 117)
The four subsystems are a first subsystem, a second subsystem, a third subsystem, and a fourth subsystem, the four motors are a first motor, a second motor, a third motor, and a fourth motor, and the system further comprises:
a fifth subsystem configured to provide three-phase power to a fifth motor of the EV, the fifth subsystem comprising three arrays, each array comprising at least two stages of modules, the stages of the at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
a sixth subsystem configured to provide three-phase power to a sixth motor of the EV, the sixth subsystem comprising three arrays, each array comprising a stage of at least two modules, the stages of the at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
Item 116. The system of item 115, comprising:
(Item 118)
Item 118. The system of item 117, wherein the chassis is a first chassis, the pack is a first pack, and the fifth and sixth subsystems are arranged within a second pack configured to fit within a second chassis of the EV that is movably coupled to the first chassis.
(Item 119)
1. A modular energy system for an electric vehicle (EV), comprising:
four subsystems configured to provide three-phase power to four motors of the EV, each subsystem comprising three arrays, each array comprising a stage of at least two modules, the stages of at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
a chassis of the EV having a first axis and a second axis perpendicular to a horizontal plane of the EV, a first dimension of the chassis along the first axis being relatively longer than a second dimension of the chassis along the second axis;
the four subsystems are arranged in a pack configured to fit within the chassis;
each module of the first and second subsystems has a first dimension aligned along the first axis and a second dimension aligned along the second axis, the second dimension of each module being relatively larger than the first dimension.
(Item 120)
Item 120. The system of item 119, further comprising a plurality of interconnection modules aligned along the second axis.
(Item 121)
The four subsystems are a first subsystem, a second subsystem, a third subsystem, and a fourth subsystem, the four motors are a first motor, a second motor, a third motor, and a fourth motor, and the system further comprises:
a fifth subsystem configured to provide three-phase power to a fifth motor of the EV, the fifth subsystem comprising three arrays, each array comprising at least two stages of modules, the stages of the at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
a sixth subsystem configured to provide three-phase power to a sixth motor of the EV, the sixth subsystem comprising three arrays, each array comprising a stage of at least two modules, the stages of the at least two modules electrically connected together and outputting an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules comprising an energy source and a converter;
Item 120. The system of item 119, comprising:
(Item 122)
Item 122. The system of item 121, wherein the chassis is a first chassis, the pack is a first pack, and the fifth and sixth subsystems are arranged within a second pack configured to fit within a second chassis of the EV that is movably coupled to the first chassis.

Details of the subject matter described herein, both with respect to its structure and operation, may be apparent from consideration of the accompanying drawings, in which like reference numerals refer to like parts. The components within the figures are not necessarily to scale, emphasis instead being placed on illustrating the principles of the subject matter. Also, all illustrations are intended to convey concepts, in which relative sizes, shapes, and other detailed attributes may be depicted diagrammatically, rather than literally or precisely.

1A-1C are block diagrams depicting exemplary embodiments of a modular energy system. 1A-1C are block diagrams depicting exemplary embodiments of a modular energy system. 1A-1C are block diagrams depicting exemplary embodiments of a modular energy system.

1D-1E are exemplary embodiments of a control device for an energy system. FIG. 1 is a block diagram depicting an embodiment. 1D-1E are exemplary embodiments of a control device for an energy system. FIG. 1 is a block diagram depicting an embodiment.

1F-1G illustrate a modular energy storage device coupled to a load and a charging source. FIG. 1 is a block diagram depicting an exemplary embodiment of a system. 1F-1G illustrate a modular energy storage device coupled to a load and a charging source. FIG. 1 is a block diagram depicting an exemplary embodiment of a system.

2A-2B are diagrams illustrating modules and control systems within an energy system. FIG. 1 is a block diagram depicting an exemplary embodiment. 2A-2B are diagrams illustrating modules and control systems within an energy system. FIG. 1 is a block diagram depicting an exemplary embodiment.

FIG. 2C illustrates an exemplary embodiment of the physical configuration of the modules. FIG.

FIG. 2D illustrates an exemplary embodiment of a physical configuration of a modular energy system. FIG. 1 is a block diagram depicting

3A-3C show exemplary embodiments of modules having various electrical configurations. FIG. 3A-3C show exemplary embodiments of modules having various electrical configurations. FIG. 3A-3C show exemplary embodiments of modules having various electrical configurations. FIG.

4A-4F are schematic diagrams depicting exemplary embodiments of energy sources. . 4A-4F are schematic diagrams depicting exemplary embodiments of energy sources. . 4A-4F are schematic diagrams depicting exemplary embodiments of energy sources. . 4A-4F are schematic diagrams depicting exemplary embodiments of energy sources. . 4A-4F are schematic diagrams depicting exemplary embodiments of energy sources. . 4A-4F are schematic diagrams depicting exemplary embodiments of energy sources. .

5A-5C are schematic diagrams depicting exemplary embodiments of an energy buffer. It is. 5A-5C are schematic diagrams depicting exemplary embodiments of an energy buffer. It is. 5A-5C are schematic diagrams depicting exemplary embodiments of an energy buffer. It is.

6A-6C are schematic diagrams depicting exemplary embodiments of a converter. 6A-6C are schematic diagrams depicting exemplary embodiments of a converter. 6A-6C are schematic diagrams depicting exemplary embodiments of a converter.

7A-7E show modular energy systems having various topologies. FIG. 1 is a block diagram depicting an exemplary embodiment of the system. 7A-7E show modular energy systems having various topologies. FIG. 1 is a block diagram depicting an exemplary embodiment of the system. 7A-7E show modular energy systems having various topologies. FIG. 1 is a block diagram depicting an exemplary embodiment of the system. 7A-7E show modular energy systems having various topologies. FIG. 1 is a block diagram depicting an exemplary embodiment of the system. 7A-7E show modular energy systems having various topologies. FIG. 1 is a block diagram depicting an exemplary embodiment of the system.

FIG. 8A is a plot depicting an example output voltage of the module.

FIG. 8B depicts an example multi-level output voltage of an array of modules; The plot.

FIG. 8C illustrates an example reference signal and 1 is a plot depicting a carrier signal.

FIG. 8D illustrates an exemplary reference signal and 1 is a plot depicting a carrier signal.

FIG. 8E illustrates an exemplary switch signal generated according to a pulse width modulation control technique. It is a plot that depicts the following.

FIG. 8F illustrates the output voltage variation from an array of modules under pulse width modulation control technique. 1 is a plot depicting an exemplary multi-level output voltage generated by superposition.

9A-9B are diagrams illustrating a controller for a modular energy system. FIG. 1 is a block diagram depicting an exemplary embodiment. 9A-9B are diagrams illustrating a controller for a modular energy system. FIG. 1 is a block diagram depicting an exemplary embodiment.

FIG. 10A illustrates a multi-phase modular energy FIG. 1 is a block diagram depicting an exemplary embodiment of a system.

FIG. 10B is an illustration of an interconnection module for the multi-phase embodiment of FIG. FIG. 1 is a schematic diagram depicting an embodiment.

FIG. 10C illustrates a schematic diagram of two sub-subsystems connected together by an interconnect module. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system having a system.

FIG. 10D illustrates a three-phase module with interconnection modules supplying auxiliary loads. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system.

FIG. 10E is an illustration of an interconnection module for the multi-phase embodiment of FIG. FIG. 1 is a schematic diagram depicting an embodiment.

FIG. 10F illustrates a three-phase module with interconnection modules supplying auxiliary loads. FIG. 2 is a block diagram depicting another exemplary embodiment of a modular energy system.

11A-11B are diagrams illustrating a modular energy 1 is a block diagram depicting an exemplary embodiment of a gas turbine engine system. 11A-11B are diagrams illustrating a modular energy 1 is a block diagram depicting an exemplary embodiment of a gas turbine engine system.

FIG. 11C illustrates an exemplary embodiment for charging a modular energy system. FIG. 1 is a flow diagram depicting

FIG. 11D is a plot depicting an example of a three-phase charging signal.

FIG. 12A illustrates a modular charger configured for DC and multi-phase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of an energy system.

FIG. 12B is a schematic diagram depicting an exemplary embodiment of a routing network. be.

FIG. 12C is a schematic diagram of a power supply configured for DC, single-phase AC, and polyphase AC charging; FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system.

FIG. 12D is a schematic diagram illustrating another exemplary embodiment of a routing network. FIG.

13A and 13D are schematic diagrams for DC, single-phase AC, and polyphase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system configured.

13B-13C and 13E-13H are exemplary diagrams of routing networks. FIG. 1 is a schematic diagram depicting an embodiment. 13B-13C and 13E-13H are exemplary diagrams of routing networks. FIG. 1 is a schematic diagram depicting an embodiment. 13A and 13D are schematic diagrams for DC, single-phase AC, and polyphase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system configured. 13B-13C and 13E-13H are exemplary diagrams of routing networks. FIG. 1 is a schematic diagram depicting an embodiment. 13B-13C and 13E-13H are exemplary diagrams of routing networks. FIG. 1 is a schematic diagram depicting an embodiment. 13B-13C and 13E-13H are exemplary diagrams of routing networks. FIG. 1 is a schematic diagram depicting an embodiment. 13B-13C and 13E-13H are exemplary diagrams of routing networks. FIG. 1 is a schematic diagram depicting an embodiment.

FIG. 14 shows a module that can be configured for DC, single-phase AC, and polyphase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system.

15A-15B and 15E show DC, single-phase AC, and polyphase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system having two subsystems configured for: 15A-15B and 15E show DC, single-phase AC, and polyphase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system having two subsystems configured for:

15C-15D and 15F-15K show additional configurations of the routing network. FIG. 1 is a schematic diagram depicting an exemplary embodiment. 15C-15D and 15F-15K show additional configurations of the routing network. FIG. 1 is a schematic diagram depicting an exemplary embodiment. 15A-15B and 15E show DC, single-phase AC, and polyphase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system having two subsystems configured for: 15C-15D and 15F-15K show additional configurations of the routing network. FIG. 1 is a schematic diagram depicting an exemplary embodiment. 15C-15D and 15F-15K show additional configurations of the routing network. FIG. 1 is a schematic diagram depicting an exemplary embodiment. 15C-15D and 15F-15K show additional configurations of the routing network. FIG. 1 is a schematic diagram depicting an exemplary embodiment. 15C-15D and 15F-15K show additional configurations of the routing network. FIG. 1 is a schematic diagram depicting an exemplary embodiment. 15C-15D and 15F-15K show additional configurations of the routing network. FIG. 1 is a schematic diagram depicting an exemplary embodiment. 15C-15D and 15F-15K show additional configurations of the routing network. FIG. 1 is a schematic diagram depicting an exemplary embodiment.

16A-16C are configured for DC, single-phase AC, and polyphase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system having three subsystems. 16A-16C are configured for DC, single-phase AC, and polyphase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system having three subsystems. 16A-16C are configured for DC, single-phase AC, and polyphase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system having three subsystems.

FIG. 17 shows four 10-V AC power supplies configured for DC, single-phase AC, and polyphase AC charging. FIG. 2 is a block diagram depicting an exemplary embodiment of a modular energy system having the following subsystems:

18A-18B are configured for DC, single-phase AC, and polyphase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system having six subsystems. 18A-18B are configured for DC, single-phase AC, and polyphase AC charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system having six subsystems.

FIG. 19A illustrates a module configured for multi-phase AC charging of arrays in parallel. FIG. 1 is a block diagram depicting an exemplary embodiment of a Joule-type energy system.

FIG. 19B illustrates DC, single-phase AC, and polyphase AC charging of arrays in parallel. FIG. 1 is a block diagram depicting an example embodiment of a modular energy system configured for

FIG. 20 illustrates a method for charging a load with DC and/or single-phase AC and bi-phase AC. FIG. 1 is a block diagram depicting an example embodiment of a modular energy system configured for multi-phase charging passing

21A-21B are configured for DC, single-phase AC, and multi-phase charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system in a delta and series arrangement. 21A-21B are configured for DC, single-phase AC, and multi-phase charging. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system in a delta and series arrangement.

FIG. 22 illustrates a multiple phase converter configured for DC, single phase AC, and multi-phase charging of a load. FIG. 1 is a block diagram depicting an exemplary embodiment of a modular energy system having multiple subsystems.

FIG. 23A shows a modular energy system in a charging station and FIG. 2 is a block diagram depicting an exemplary embodiment of a modular energy system in an EV.

FIG. 23B is a schematic diagram of a system configured for DC, single-phase AC, and multi-phase charging of multiple EVs. FIG. 2 is a schematic diagram depicting an exemplary embodiment of a modular energy system in a charging station.

FIG. 24 shows a modular energy system within the interior area of an EV chassis. FIG. 1 is a schematic diagram depicting an exemplary embodiment.

25A-25B are diagrams showing the internal structure of the EV chassis and the two motors. FIG. 1 is a schematic diagram depicting an exemplary embodiment of a modular energy system configured to provide power for a 25A-25B are diagrams showing the internal structure of the EV chassis and the two motors. FIG. 1 is a schematic diagram depicting an exemplary embodiment of a modular energy system configured to provide power for a

FIG. 26 shows the internal area of the EV chassis, which contains the power for the three motors. FIG. 2 is a schematic diagram depicting an exemplary embodiment of a modular energy system configured to provide

27A-27B are diagrams showing the four motors in the interior area of the EV chassis. FIG. 1 is a schematic diagram depicting an example embodiment of a modular energy system configured to provide power for a 27A-27B are diagrams showing the four motors in the interior area of the EV chassis. FIG. 1 is a schematic diagram depicting an example embodiment of a modular energy system configured to provide power for a

28A-28C are diagrams showing the internal regions of the first and second chassis of the EV. FIG. 1 is a schematic diagram depicting an example embodiment of a modular energy system configured to provide power for six motors. 28A-28C are diagrams showing the internal regions of the first and second chassis of the EV. FIG. 1 is a schematic diagram depicting an example embodiment of a modular energy system configured to provide power for six motors. 28A-28C are diagrams showing the internal regions of the first and second chassis of the EV. FIG. 1 is a schematic diagram depicting an example embodiment of a modular energy system configured to provide power for six motors.

FIG. 29A shows an active suspension or active steering mechanism. FIG. 1 is a block diagram depicting an example embodiment of a modular energy system configured to provide power for an electric motor in a vehicle configuration.

FIG. 29B is a diagram of a modular energy system for use in a modular energy system. FIG. 2 is a block diagram depicting an exemplary embodiment of a module.

29C-29D are diagrams showing a configuration of a modular energy system for use in FIG. 2 is a schematic diagram depicting an exemplary embodiment of a module for 29C-29D are diagrams showing a configuration of a modular energy system for use in FIG. 2 is a schematic diagram depicting an exemplary embodiment of a module for

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

Before describing exemplary embodiments relating to charging and discharging modular energy systems, it is useful to first describe these underlying systems in more detail. With reference to Figures 1A-10F, the following sections describe various applications in which modular energy system embodiments may be implemented, embodiments of control systems or devices for modular energy systems, configurations of modular energy system embodiments relative to charging sources and loads, embodiments of individual modules, embodiments of topologies for arrangement of modules in the system, embodiments of control methodologies, embodiments of balanced operating characteristics of modules in the system, and embodiments of uses of interconnected modules.
Examples of uses

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

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

In describing embodiments herein, reference may be made to a particular stationary application (e.g., power grids, micro-power grids, data centers, cloud computing environments) or mobile application (e.g., electric vehicles). Such references are made for ease of discussion and are not meant to limit a particular embodiment to use only that particular mobile or stationary application. Embodiments of a system for providing power to a motor can be used in both mobile and stationary applications. While certain configurations may be more suitable for some applications over others, all exemplary embodiments disclosed herein are capable of use in both mobile and stationary applications unless otherwise stated.
Example of a module-based energy system

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The energy source 206 can be configured as any of the energy source types described herein (e.g., a battery, HED capacitor, fuel cell, or other, as described with respect to FIGS. 4A-4D ). Ports IO1 and IO2 of the energy source 206 can be connected to ports IO1 and IO2, respectively, of the energy buffer 204. The energy buffer 204 can be configured to buffer or filter high and low frequency energy waves arriving at the buffer 204 through the converter 202, which may otherwise degrade the performance of the module 108. The topology and components for the buffer 204 are selected to accommodate the maximum allowable amplitude of these high frequency voltage pulses. Several (non-exhaustive) exemplary embodiments of the energy buffer 204 are depicted in the schematic diagrams of FIGS. 5A-5C . In FIG. 5A , the buffer 204 is configured to filter electrolytic and/or film capacitors C _E.B. In FIG. 5B, the buffer 204 includes two inductors L _EB1 and L _EB2 and two electrolytic and/or film capacitors C _EB1 and C _EB2 5C, the buffer 204 is formed by two inductors L _EB1 and L _EB2 and two electrolytic and/or film capacitors C _EB1 and C _EB2 and diode D _E.B. and a quasi-Z-source network 720 formed by

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

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

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

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

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

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

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

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

6B and 6C are schematic diagrams depicting exemplary embodiments of converters 202B and 202C, respectively. Converter 202B includes switch network portions 601 and 602A. Portion 601, in a similar manner to converter 202A, includes switches S3-S6 configured as a full bridge and configured to selectively couple IO1 and IO2 to either IO3 and IO4, thereby varying the output voltage of module 108B. Portion 602A includes switches S1 and S2 configured as a half bridge and coupled between ports IO1 and IO2. A coupled inductor L _C is connected between port IO5 and node 1, which exists between switches S1 and S2, such that switch portion 602A is a bidirectional converter that can regulate (boost or buck) voltage (or conversely, current). Switch portion 602A ... _DCL2 Two different voltages can be generated at node 1, 0 and 1. The current drawn from or input to energy source 202B can be controlled by, for example, a pulse width modulation technique or a hysteretic control method to commutate switches S1 and S2 through coupled inductor L. _C The output voltage can be controlled by adjusting the voltage on the output. Other techniques can also be used.

Converter 202C differs from 202B in that switch portion 602B includes switches S1 and S2 configured as a half bridge and coupled between ports IO5 and IO2. _C is connected between port IO1 and node 1, which is between switches S1 and S2, such that switch portion 602B is configured to regulate the voltage.

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

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

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

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

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

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

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

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

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

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

To protect the energy buffer 204, the LCD 114 may receive one or more monitored voltages, temperatures, and currents from the energy buffer 204 (or monitor circuitry). The monitored voltages are monitored for each basic component (e.g., C _E.B. , C _EB1 , C _EB2 , L _EB1 , L _EB2 , D _E.B. ) or the voltage of the group of basic components of buffer 204 as a whole (e.g., between IO1 and IO2 or between IO3 and IO4). Similarly, the monitored temperatures and currents may be at least one, preferably all, of the temperature and current of each basic component of buffer 204 independent of the other components, or the temperature and current of the group of basic components of buffer 204 as a whole, or any combination thereof. The monitored signals may be status information with which LCD 114 may perform one or more of the following: setting or outputting a warning or alarm indication, communicating status information to MCD 112, or control converter 202 may adjust (increase or decrease) the utilization of source 206 and module 108 as a whole for buffer protection.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The controller 906 can generate Mi for each module 108 using status information of any type or combination of types described herein (e.g., SOC, temperature (T), Q, SOH, voltage, current). For example, using SOC and T, a module 108 can have a relatively high Mi if its SOC is relatively high and its temperature is relatively low compared to other modules 108 in the array 700. If either of the SOCs are relatively low or T is relatively high, that module 108 can have a relatively low Mi resulting in less utilization than other modules 108 in the array 700. The controller 906 can determine Mi such that the sum of the module voltages does not exceed Vpk. For example, Vpk can be calculated by multiplying the voltage of each module's source 206 by the product of Mi for that module (e.g., Vpk=M ₁ V ₁ +M ₂ V ₂ +M ₃ V ₃ ． ． ． +M _N V _N etc.) Different combinations of modulation indexes, and therefore individual voltage contributions by the modules, may be used, but the total generated voltage should remain the same.

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

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

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

Controllers 900 and 950 (and balancing controllers 906 and 910) can be implemented in hardware, software, or a combination thereof within control system 102. Controllers 900 and 950 can be implemented within MCD 112, distributed partially or completely among LCD 114, or may be implemented as discrete controllers separate from MCD 112 and LCD 114.
Exemplary embodiments of an interconnect (IC) module

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

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

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

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

Because of phase-to-phase balance, relatively more energy from source 206 can be delivered to any one or more of arrays 700-PA through 700-PΩ that are at a relatively low state of charge compared to the other arrays 700. This complementary delivery of energy to a particular array 700 allows the energy output of those cascaded modules 108-1 through 108-N within that array 700 to be reduced relative to the undelivered phase arrays.

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

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

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

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

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

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

Additionally, the IC module can be configured to exchange energy between two or more subsystems of the system 100. FIG. 10C is a block diagram depicting an exemplary embodiment of the system 100 with a first subsystem 1000-1 and a second subsystem 1000-2 interconnected by an IC module. Specifically, the subsystem 1000-1 is configured to supply three-phase power PA, PB, and PC to a first load (not shown) using system I/O ports SIO1, SIO2, and SIO3, while the subsystem 1000-2 is configured to supply three-phase power PD, PE, and PF to a second load (not shown) using system I/O ports SIO4, SIO5, and SIO06, respectively. For example, the subsystems 1000-1 and 1000-2 can be configured as different packs supplying power for different motors of an EV, or as different racks supplying power for different micro-power systems.

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

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

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

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

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

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

Exemplary embodiments relating to charging of the modular energy system 100 will now be described with reference to Figures 11A-23B. These embodiments can be implemented with any aspect of the system 100 described with respect to Figures 1A-10F, unless otherwise noted or logically improbable. Thus, many of the variations discussed herein will not be repeated with respect to each of the following charging embodiments.

Charging embodiments will be described with reference to the type and amount of signals available from the charging source to supply charge to the various modules of the system 100. These embodiments are categorized into three main types: DC charging, where the charging source provides a high-voltage DC charging signal; single-phase AC charging, where the charging source provides a single high-voltage AC charging signal; and multi-phase AC charging, where the charging source provides two or more high-voltage AC charging signals with different phase angles. For convenience, multi-phase charging embodiments will be described with respect to a system 100 having three phases, and in some cases six phases, but the present subject matter is applicable to any system 100 having two or more arrays that charge and discharge using two or more different phases. The charging source can have a variety of configurations depending on the particular application. For stationary applications, the charging source can be the power grid, supplied by a utility company or other power provider, regardless of the energy source type. The charging source can also be a renewable energy source, such as an array of solar panels, wind turbines, and the like. For mobile applications, the charging source can also be the power grid or a renewable energy source that is supplied to the electric vehicle, often using a charging station that provides DC, single-phase AC, or poly-phase AC power.

11A and 11B are block diagrams depicting an exemplary embodiment of a three-phase system 100 configured for use in a locomotion application to supply three-phase power for a motor 1100 and having interconnection modules 108IC-1 and 108IC-2 configured to supply power to auxiliary loads 301 and 302. System 100 includes a switch 1108-PA located between SIO1 and I/O port 1 of module 108-1 of array 700-PA, a switch 1108-PB located between SIO2 and I/O port 1 of module 108-1 of array 700-PB, and a switch 1108-PC located between SIO3 and I/O port 1 of module 108-1 of array 700-PC. Each switch 1108 is independently controllable by a control signal applied via a control line by control system 102 (e.g., MCD 112) (e.g., FIGS. 1A-1C) or by external control device 104 (e.g., FIGS. 1A, 1B, 1D, 1E).

In this and other embodiments described herein, motor 1100 can be an electric motor, such as a permanent magnet (PM), induction, or switched reluctance motor (SRM). System 100 is a three-phase system, having an IC module and an auxiliary load, here and in many of the following embodiments, but the charging subject matter can be applied to embodiments having one or more phases, with or without an IC module and an auxiliary load, as well.

Switches 1108-PA, 1108-PB, and 1108-PC switchably connect the three-phase charging signals from the ports of the three-phase charging connector 1102 to their respective phase module arrays (700-PA, 700-PB, and 700-PC) via lines 1111. The charging connector 1102 can be coupled to the charging source 150 using the charging source's charging connector 1104 and cable 1106. A neutral connection is not required for three-phase charging. The switch 1108 is preferably an electromechanical switch, although a solid-state repeater (SSR) may also be used. Electromechanical switches offer high reliability in keeping the motor coils or windings connected to the modular energy source in the event of a power loss.

System 100 also includes monitor circuits 1110-PA, 1110-PB, and 1110-PC connected between switches 1108-PA, 1108-PB, and 1108-PC and arrays 700-PA, 700-PB, and 700-PC, respectively. Monitor circuits 1110-PA, 1110-PB, and 1110-PC can measure any one or more of the current, voltage, and phase of signals passing through nodes NPA, NPB, and NPC, respectively, and output these measurements to control system 102 via data lines (not shown) for use in controlling module 108 during charging and discharging.

In FIG. 11A , the switches 1108 are each two-conductivity position switches (e.g., single-pole, double-throw (SPDT)). When the switches 1108 are in position 1, the array 700 is connected to the motor 1100 and the connectors 1102 are decoupled and not energized. The switches 1108 default to position 1 as their normal position and assume this position when no control signal is applied. In the event of a power loss or other situation in which the switches 1108 are decoupled from the control signal, they can revert to position 1 so as not to leave the motor coils unconnected. When a control signal (e.g., a common signal) is applied, the switches 1108 move to position 2, coupling the connectors 1102 to the array 700. When in position 2, the system 100 can be charged through the connectors 1102. Application of the control signal can occur automatically when the system 100 detects a physical coupling of the charging source connector 1104 and the system connector 1102 or detects the presence of a multi-phase voltage at the connectors 1102. Application of the control signal may also be conditioned on the motor being turned off. Removal of the control signal, such as after disconnection of connector 1104 or detection of the absence of multi-phase charging voltage at connector 1102, causes switch 1108 to return to position 1.

In the embodiment of FIG. 11B , the switch 1108 is again an on/off switch (e.g., a switch having an open and closed state, such as a single-pole single-throw (SPST) switch) that is controllable by application of a control signal (not shown). The array 700 is always connected to the connector 1102 and therefore always energized, so the connector 1102 is configured such that its internal conductors are insulated from user contact. For example, the conductors may be stored deep within the charging receptacle of the connector 1102. The design of the connector 1102 is preferably sufficient to prevent user contact (e.g., shock or short circuit) such that the connector 1102 may be energized even when the motor 1100 is running. The closed position is the default position of the switch 1108 in this embodiment to keep the system 100 connected to the motor 1102, since damage to the motor and/or converter 202 could occur if the switch 1108 were open during operation of the motor 1100. Application of the control signal causes the switch 1108 to open, which disconnects the module 108 from the motor 1100 and allows charging through the connector 1102. Although three SPST switches 1108 are shown here, in an embodiment with a closed coil motor 1100, one of the SPST switches 1108 can be omitted, e.g., only two of the three SPST switches 1108 can be present (for any two of phases PA, PB, PC) since no current would pass through the motor 1100 when two of the three coils are electrically disconnected. The third coil can remain electrically connected to the system 100 during charging.

11C is a flow diagram depicting an exemplary embodiment of a method 1150 for charging, applicable to the embodiments of FIGS. 11A-11B and other embodiments described herein. At 1152, the system 100 detects a connection of the charging source 150 with the connector 1102. As described herein, this may occur by the control system 102 detecting physical contact between the charging source connector 1104 and the system connector 1102, or by the system 100 sensing a charging signal voltage using a sensor in the connector 1102. At 1154, after detecting the connection of the charging source 150, the switch 1108 may be switched from a discharging position to a charging position (e.g., position 2 for FIG. 11A or open for FIG. 11B).

At 1156, the charging signal provided by charging source 150 is monitored by monitor circuitry 1110 and this information is output to control system 102. FIG. 11D is a plot depicting three-phase charging signals 1112-PA, 1112-PB, and 1112-PC. At 1158, control system 102 outputs control signals to each module 108 of system 100 that cause the converter 202 of each module 108 to switch appropriately for charging. Steps 1156 and 1158 are performed in parallel, providing control system 102 with a continuous assessment of the voltage, current, and/or phase of the charging signal while adjusting the switching scheme for each module 108 as appropriate.

When switching modules 108 in step 1158, the control system 102 (e.g., MCD 112, LCD 114) generates a switching signal for each converter 202 of each module 108, as described elsewhere herein. Each converter 202 supplies +V _DCL A first state presents −V _DCL , and a third state in which the module is bypassed (shorted) and presents zero voltage at ports 1 and 2. The switching can be controlled such that each energy source 206 of each module 108 can be charged based on the direction of current through each array 700.

The control system 102 can be programmed to control the switching of each module 108 to minimize distortion and deviations within each phase of the array 700. This can be accomplished by targeting the power factor (PF) to be at or near one (unity), according to (1).

where I1rms is the root mean square value of the fundamental component of the current in the array 700 of a particular phase (e.g., array 700-PA), Irms is the root mean square value of the sum of all significant harmonics (I1+I2+I3...) of the current of a particular phase, and Θ is the phase angle between the voltage and current of a particular phase. To achieve a PF at or near unity, the control system 102 can control the switching such that the sum of the currents of each phase (e.g., as measured at the NPA, NPB, NPC) is zero or close to zero (e.g., within a threshold) at all times, and the displacement (Θ) between the current and voltage of each phase is zero or close to zero (e.g., within a threshold) at all times.

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

Alternatively, modules 108 with relatively fewer SOC stages can initially receive relatively more charge until system 100 reaches a relatively balanced SOC state, at which point all modules 108 can be charged in a manner such that the system has a relatively balanced SOC state at all times (e.g., all fully functional modules 108 are within 1% of one another in terms of SOC). This approach has the advantage that if charging is stopped prior to system 100 reaching capacity, system 100 will terminate the charging process in a relatively balanced state.

11C, the charging process 1150 can continue until 1160, when the module 108 is fully (or properly) charged or the system 100 detects a disconnection of the charging source 150, at which point the switches 1108 can be transitioned from their charging position back to their default position for the discharging state (e.g., position 1 for FIG. 11A and the closed position for FIG. 11B).

In the embodiment described herein, the control system 102 can utilize the incoming AC charging signal (or a representation thereof) for each phase as a reference waveform for the individual arrays 700, or in the case of DC charging, as a different reference, to control the switching by generation of switching signals for each module 108 according to PWM techniques such as those described herein. The modulation index for the switching circuitry of each module 108 can be adjusted to maintain a power factor at or near unity by selectively charging and discharging each module for various lengths of time. Charging can also be performed while maintaining or targeting a balanced condition in one or more operating characteristics of the system 100, as previously described herein. The modulation index (Mi) can also be adjusted to target a relatively balanced temperature across all modules and perform charging while placing emphasis on charging for the energy sources 206 with the relatively lowest SOC by assigning the relatively highest modulation index to those modules 108.

Additionally, with respect to electrochemical battery source 206, the length of the charging pulse applied by converter 202 to source 206 can be maintained to have a length, e.g., less than 5 milliseconds, to encourage the occurrence of electrochemical storage reactions within the battery without the occurrence of significant side reactions that may lead to degradation. Such pulses can be applied at high C-rates (e.g., 5C to 15C and above) to allow for fast charging of source 206. Examples of such techniques that can be used in conjunction with all embodiments described herein are described in International Application No. PCT/US20/35437, entitled "Advanced Battery Charging on Modular Levels of Energy Storage Systems," which is incorporated herein by reference for all purposes.

In the embodiment of Figures 11A-11B, modules 108IC-1 and 108IC-2 are interconnected with each other and also interconnected between different phases of array 700. During charging, switch portions 604 (see, e.g., Figure 10E) of modules 108IC can be continuously switched such that current flows through either S7 or S8 at a 50-50 duty cycle. Energy sources 206 of modules 108IC can be charged by adjusting the duty cycle of each switch portion 604 to a state where the aggregate current over time through each portion 604 charges sources 206 of those modules 108IC. Alternatively, switch portions 604 of modules 108IC can be switched only on a needed basis to direct current through modules 108IC, e.g., to steer current while charging sources 206 of modules 108IC, or to steer current without charging sources 206. The switching of the module 108 IC can also be used to minimize distortion and displacement within each array 700. For all embodiments having auxiliary loads, during charging, the control system 102, through the switch portion 602A (FIG. 10E), can continue to regulate the voltage for the auxiliary loads 302 so that power can be maintained for the auxiliary systems if needed. In the context of an electric vehicle, this can maintain power for on-board networks, displays, HVAC, etc.

Although charging is described with reference to a PWM control technique, in alternative embodiments, a hysteresis technique can be used. Other custom techniques based on PWM or hysteresis may also be used.
Exemplary embodiments of DC and single phase charging with motor bypass

The multi-phase configuration of system 100 can also be charged using DC or single-phase AC charging sources. FIG. 12A is a block diagram depicting an example embodiment of three-phase system 100 configured similarly to the embodiment of FIG. 11A, but with routing circuitry 1200 that allows for DC and/or single-phase AC charging capability in addition to the multi-phase AC charging capability, where all charging can occur in a manner that bypasses motor 1100. Routing circuitry 1200 can be coupled between multi-phase charging connector 1102 and three-phase charging wires 1111. Routing circuitry 1200 can have at least one connector 1202 that can receive DC charging signals (DC+ and DC-) and/or AC charging signals (AC line (L) and neutral (N)). These connections can be shared, as shown in FIG. 12A, or can be separate such that different conductors are utilized for DC and single-phase AC. A variety of different configurations and types of circuitry can be used for routing circuitry 1200, depending on the type of charging signal being routed (DC or single phase AC) and whether the embodiment provides for selective disconnection of charging connectors 1102 and 1202 from system 100. Exemplary embodiments of routing circuitry 1200 are described in more detail in Figures 12B-21B.

The switch 1108 can be part of a single switching assembly 1250 configured to conduct the high currents required during the charging and discharging phases. The assembly may be configured as a discrete single device or housing. The assembly 1250 can have one or more inputs and receive switching control signals from the control system 102. In some embodiments, the monitor circuit 1110 can be integrated within the assembly 1250 and the control signals to and data output from the circuit 1110 can be routed to the control system 102 through an IO port of the assembly 1250.

12B is a schematic diagram depicting an exemplary embodiment of routing circuitry 1200 configured to provide DC charging capability using three-phase lines 1111 with solid-state (or semiconductor) repeaters (SSRs). Routing circuitry 1200 has I/O ports 1201-1 and 1201-2 connected to connector 1202, and I/O ports 1204-PA, 1204-PB, and 1204-PC for each phase PA, PB, PC that may be connected to charging line 1111. Routing circuitry 1200 can be controlled to selectively output each of the DC+ and DC- signals on input 1201 to one or more of three different outputs 1204. Circuitry 1200 also includes one or more I/O ports 1206-1 through 1206-4 for control signals CS1-CS4, respectively, that control the routing of each input 1201 to each output 1204. The control signals CS1-CS4 may be generated and provided by a control system 102 (not shown).

The use of SSRs isolates the system 100 and the EV from the DC charger, which allows additional isolation circuitry in the DC charger (e.g., high frequency transformers and inverters) to be completely removed or omitted. This can simplify the DC charger implementation and substantially reduce costs. In this embodiment, the SSR circuitry includes four thyristors T1, T2, T3, and T4. Each thyristor can be selectively placed in a unidirectional current conducting (closed) state or a non-conducting (open) state by application of a control signal (CS1, CS2, CS3, CS4, respectively) from the control system 102.

During the charging phase, the switches 1108 may each be transitioned to charging position 2, or alternatively, only the switches 1108 of the arrays 700 that are being charged may be switched to position 2, with the switches 1108 of any arrays 700 remaining in position 1 and not being charged. Thus, some commutation of the switches 1108 may be necessary during the charging phase.

To charge the modules 108 of arrays 700-PA and 700-PB (including modules 108IC-1 and 108IC-2, connected in parallel), control system 102 can place T1 and T3 in a conducting state with application of control signals CS1 and CS3, respectively, and T2 and T4 in a non-conducting state with application of control signals CS2 and CS4, respectively. Current passes from DC+ port 1201-1 through T1 to I/O port 1204-PA, which is connected to PA line 1111 from three-phase charging connector 1102. Current bypasses motor 1100 and passes through array 700-PA through switch 1108-PA. Each module 108-1 through 108-N of array 700-PA can be selectively charged as described herein. Current passes through module 108IC-1 (e.g., switch S7 of portions 604-PA and 604-PB or switch S8 of portions 604-PA and 604-PB as described with respect to FIG. 10E) and through array 700-PB, so that each module 108-1 through 108-N of array 700-PB can be selectively charged with respect to the opposite current direction. Current passes through switch 1108-PB, via I/O port 1204-PB, into routing circuitry 1200, then through T3, and out through DC-port 1201-2.

To charge the modules 108 (including modules 108IC-1 and 108IC-2) of arrays 700-PB and 700-PC, control system 102 can place T2 and T4 in a conducting state with application of control signals CS2 and CS4, respectively, and place T1 and T3 in a non-conducting state with application of control signals CS1 and CS3, respectively. Current passes from DC+ port 1201-1, through T2, to I/O port 1204-PB, which is connected to PB line 1111 from three-phase charging connector 1102. Current bypasses motor 1100 and passes through switch 1108-PB and through array 700-PB. Each module 108-1 through 108-N of array 700-PB can be selectively charged as described herein. Current passes through module 108IC-1, then through module 108IC-2 (e.g., using switches S7 together or S8 together of portions 604-PB and 604-PC in FIG. 10E) through array 700-PC, and each module 108-1 through 108-N of array 700-PC can also be selectively charged, considering the opposite current direction. The current passes through switch 1108-PC, through I/O port 1204-PC, then through T4, into routing network 1200, and exits through DC-port 1201-2.

To charge the modules 108 (including modules 108IC-1 and 108IC-2) of arrays 700-PA and 700-PC, control system 102 can place T1 and T4 in a conducting state with application of control signals CS1 and CS4, respectively, and place T2 and T3 in a non-conducting state with application of control signals CS2 and CS3, respectively. Current passes from DC+ port 1201-1, through T1, to I/O port 1204-PA. Current bypasses motor 1100, passes through switch 1108-PA, and through array 700-PA. Each module 108-1 through 108-N of array 700-PA can be selectively charged as described herein. Current passes through module 108IC-1, then through module 108IC-2 (e.g., using switches S7 together or S8 together of portions 604-PA and 604-PC in FIG. 10E) through array 700-PC, and each module 108-1 through 108-N of array 700-PC can also be selectively charged, given the opposite current direction. Current passes through switch 1108-PC, through I/O port 1204-PC, then through T4, into routing circuitry 1200, and exits through DC/port 1201-2.

In each of the foregoing embodiments, module 108IC-1 and interconnected module 108IC-2 can charge their energy sources 206 by routing inflow current through sources 206 via appropriate combinations of switches in portions 604-PA, 604-PB, and 604-PC prior to outputting the current from module 108IC.

12C is a schematic diagram depicting an example embodiment of routing circuitry 1200 configured to enable both DC and single-phase AC charging through connector 1202 in conjunction with a solid-state repeater (SSR). Connector 1202 can be connected to either a single-phase charging cable, which in turn is connected to a single-phase charging source, or a DC charging cable, which in turn is connected to a DC charging source. In this embodiment, the SSR circuitry includes four triacs TR1, TR2, TR3, and TR4. Each triac can be selectively placed in a bidirectional current conducting (closed) state or a non-conducting (open) state by application of a control signal (CS1, CS2, CS3, CS4, respectively) from control system 102.

For single phase AC charging, the routing circuitry 1200 can selectively output each of the AC(L) and AC(N) signals at I/O ports 1201-1 and 1201-2, respectively, to one or more of three different I/O ports 1204-PA, 1204-PB, and 1204-PC, which are connected to different lines 1111 from the three-phase charging connector 1102, which are in turn connected to arrays 700-PA, 700-PB, and 700-PC, respectively. For DC charging, the routing circuitry 1200 can similarly selectively output each of the DC+ and DC- signals at input 1201 to one or more of three I/O ports 1204 for provision to array 700. The selective routing is controlled by control signals CS1-CS4 provided by control system 102 and applied to one or more control inputs 1206-1 through 1206-4.

In single-phase AC charging, the triacs can assume the same states as the thyristors in DC charging when charging the same pair of arrays 700. The use of a bidirectional triac (or other bidirectional SSR device) allows the current flow directionality to change when the single-phase AC charging signal transitions between positive and negative polarity. Whether DC or single-phase AC charging, while the signal is positive, charging can be performed in a manner similar to that of FIGS. 12A-12B, except with triacs TR1-TR4 instead of thyristors T1-T4. The current flow is in the opposite direction when the single-phase AC charging signal is in the negative half of the cycle, which can then be performed.

To charge the modules 108 (including modules 108IC-1 and 108IC-2) of arrays 700-PA and 700-PB when the AC signal is negative, control system 102 can place TR1 and TR3 in a conducting state with application of control signals CS1 and CS3, respectively, and place TR2 and TR4 in a non-conducting state with application of control signals CS2 and CS4, respectively. Current passes from AC neutral (N) port 1201-2, through TR3, to I/O port 1204-PB, from where it bypasses motor 1100, through switch 1108-PB, and through array 700-PB. Each module 108-1 through 108-N of array 700-PB can be selectively charged as described herein. Current passes through array 700-PA, through module 108IC-1 (e.g., using switches S7 together or S8 together of portions 604-PA and 604-PB of FIG. 10E), and each module 108-1 through 108-N of array 700-PA can be selectively charged, with respect to the opposite current direction. Current passes through switch 1108-PA, via I/O port 1204-PA, then through TR1, into routing circuitry 1200, and out through AC line (L) port 1201-1.

When the AC signal is negative, to charge the modules 108 (including modules 108IC-1 and 108IC-2) of arrays 700-PB and 700-PC, control system 102 can place TR2 and TR4 in a conducting state with application of control signals CS2 and CS4, respectively, and TR1 and TR3 in a non-conducting state with application of control signals CS1 and CS3, respectively. Current passes from AC(N) port 1201-2, through TR4, to I/O port 1204-PC, bypassing motor 1100, through switch 1108-PC, and through array 700-PC. Each module 108-1 through 108-N of array 700-PC can be selectively charged as described herein. The current passes through module 108IC-2, then through module 108IC-2 (e.g., using switches S7 together or S8 together of portions 604-PB and 604-PC in FIG. 10E) through array 700-PB, and each module 108-1 through 108-N of array 700-PB can also be selectively charged, with consideration for the opposite current direction. The current passes through switch 1108-PB, through I/O port 1204-PB, then through TR2, into routing circuitry 1200, and exits through AC(L) port 1201-1.

When the AC signal is negative, to charge the modules 108 (including modules 108IC-1 and 108IC-2) of arrays 700-PA and 700-PC, control system 102 can place TR1 and TR4 in a conducting state with application of control signals CS1 and CS4, respectively, and place TR2 and TR3 in a non-conducting state with application of control signals CS2 and CS3, respectively. Current passes from AC(N) port 1201-2, through TR4, to I/O port 1204-PC. Current bypasses motor 1100, passes through switch 1108-PC, and through array 700-PA. Each module 108-1 through 108-N of array 700-PC can be selectively charged as described herein. Current passes through module 108IC-2 and then through module 108IC-1 (e.g., using switches S7 together or S8 together of portions 604-PA and 604-PC in FIG. 10E) through array 700-PA, and each module 108-1 through 108-N of array 700-PA can also be selectively charged, with consideration for opposite current directions. Current passes through switch 1108-PA, through I/O port 1204-PA, then through TR1, into routing circuitry 1200, and exits through AC(L) port 1201-1.

Figure 12D is a schematic diagram depicting an exemplary embodiment of routing circuitry 1200 configured to enable DC and single-phase AC charging using a combination of thyristors and diodes. DC charging is provided by connector 1202-1, coupled to DC+ input 1201-1 and DC- input 1201-2, whose signal is routed to three-phase line 1111 by section 1241, having thyristors T1-T4, in a manner similar to that of Figure 12B (control input 1206 is not shown). Single-phase AC charging is provided by connector 1202-2, coupled to AC(L) input 1201-3 and AC(N) input 1201-4, whose signal is routed to line 1111 by section 1242, having diodes D1-D4. When the AC charging signal is positive, diodes D2 and D4 are on and D1 and D3 are off, and when the AC signal is negative, diodes D1 and D3 are on and D2 and D4 are off. The AC signal presented in section 1241 can then be routed to line 1111 as desired. Diodes D1-D4 are high voltage diodes that correspond to the voltages applied to DC ports 1201-1 and 1201-2. The embodiment of Figure 12D allows for cost reduction through the use of diodes D1-D4 as opposed to triacs.

Use of the SPDT switch configuration of Figures 11A and 12A provides for automatic disconnection and isolation of the charge connectors 1102 and 1202 when the switch 1108 is in discharge position 1. Similarly, the motor 1100 is automatically disconnected and isolated when the switch 1108 is in charge position 2. Using the SPST switch 1108, as in the embodiment of Figure 11B, the motor 1100 is disconnected when in the charge state. However, the charge connector remains connected when the switch 1108 is closed and the motor 1100 is connected for the discharge state. Figures 13A-13D depict an example embodiment using the SPST switch 1108 and having the ability to selectively disconnect the charge connector while the motor 1100 is connected and the system 100 is in the discharge state.

FIG 13A is a block diagram depicting system 100 similar to that of FIG 11B, but configured with SPST switch 1108 with routing circuitry 1200 to allow DC and/or single phase AC charging in addition to polyphase AC charging while bypassing motor 1100. As in FIG 12A, in this embodiment switch 1108 can be located within integrated switch assembly device 1250. FIG 13B and 13C are schematic diagrams depicting additional exemplary embodiments of routing circuitry 1200 with switches 1331-PA, 1331-PB, and 1331-PC configured to selectively disconnect lines 1111-PA, 1111-PB, and 1111-PC connected between arrays 700-PA, 700-PB, and 700-PC and connector 1102. Switch 1331 is configured as an electromechanical repeater in this embodiment. Each of the switches 1331 can be controlled using a control signal received at the I/O port 1206 (control connections not shown). The control system 102 can generate and output a control signal to the switch 1331. The SPST switch 1108 defaults to a closed position and is configured to keep the motor 1100 connected to the system 100, while the switch 1331 defaults to an open position and is configured to keep the charging connectors 1102 and 1202 disconnected from the system 100. The embodiment of FIG. 13B is otherwise configured to operate similarly to that of FIG. 12C, which is otherwise configured to operate similarly to that of FIG. 12D. The embodiment of FIG. 12B can also be used if the switch 1331 is included in the circuitry 1200.

Figure 13D is a block diagram depicting an exemplary embodiment similar to that of Figure 13A but with switch 1331 moved from routing circuitry 1200 to switch assembly 1250. In this embodiment, routing circuitry 1200 can be configured similar to that of Figures 12B, 12C, or 12D.

13E-13H are schematic diagrams depicting exemplary embodiments of routing circuitry 1200 for use with the embodiment of FIG. 13A, where switches 1331 are configured as triacs, which have relatively lower cost and higher switching speed than electromechanical relays. Although these embodiments depict the use of triacs, other SSR types can also be used. In each of these embodiments, the controllable triacs and thyristors can be controlled by control signals generated and provided by the control system 102. For ease of illustration, control lines and ports for routing these control signals to each of the controllable thyristors and triacs are not shown. In FIG. 13E, switches 1331 in the form of triacs TR1-TR3 are positioned between the thyristor section 1241 and the three-phase connector 1102. In another embodiment, triacs TR1-TR3 can be positioned on the opposite (array) side of the section 1241 connection. In yet another embodiment, triacs TR1-TR3 can be positioned within switch assembly 1250 (and used with routing circuitry 1200 of FIGS. 12B-12D), similar to the embodiment of FIG. 13D.

Figure 13F depicts another exemplary embodiment in which the number of components from the embodiment of Figure 13E has been reduced by consolidation and reconfiguration while maintaining the same functionality. Here, section 1242 remains generally the same and is coupled to lines 1111-PA and 1111-PC between section 1334 and connector 1102. A DC charging signal is input to multi-phase charging connector 1102 with a DC+ signal input to the PA terminal and a DC- signal input to the PC terminal. Section 1334 includes a triac on each of lines 1111, with thyristor T1 coupled between the array sides of triacs TR1 and TR2 and thyristor T2 coupled between the array sides of triacs TR2 and TR3. To charge arrays 700-PA and PB, triacs TR1 and TR3 and thyristor T2 are opened and triac TR2 and thyristor T1 are closed. To charge arrays 700-PB and PC, triacs TR1 and TR3 and thyristor T1 are open and triac TR2 and thyristor T2 are closed. To charge arrays 700-PA and PC, triacs TR1 and TR3 are open and triac TR2 and thyristor T1 and T2 are closed.

Figure 13G depicts an embodiment in which the dual DC and single phase AC triac configuration of Figure 12C is connected to wire 1111, and a switch 1331 in the form of triacs TR1-TR3 is positioned between those connections and connector 1102. Figure 13H depicts another exemplary embodiment in which the number of components from the embodiment of Figure 13G has been reduced by consolidation and reconfiguration while maintaining the same functionality. Here, triac TR4 is coupled between the array sides of triacs TR1 and TR2, and triac TR5 is coupled between the array sides of triacs TR2 and TR3. To charge arrays 700-PA and PB, triacs TR1, TR3, and TR5 are opened and triacs TR2 and TR4 are closed. To charge arrays 700-PB and PC, triacs TR1, TR3, and TR4 are open and triacs TR2 and TR5 are closed. To charge arrays 700-PA and PC, triacs TR1 and TR3 are open and triacs TR2, TR4, and TR5 are closed.

In the embodiments described herein, connector 1202 can be a separate and discrete connector from that of three-phase charging connector 1102, whether configured for DC only, single-phase AC only, or both, or connectors 1102 and 1202 can be combined within a single location on the EV.

Different approaches can be used to charge each pair of arrays 700. In one exemplary embodiment, when charging arrays 700-PA and PB, charging can be performed until both arrays 700 reach a desired level or threshold (e.g., 50%). Then, when charging arrays 700-PB and PC, charging can be performed until array 700-PB reaches 100% and array 700-PC reaches 50%. Then, when charging arrays 700-PA and PC, charging can be performed until both arrays 700 reach 100%. In another exemplary embodiment, the routing circuitry 1200, switches 1108, and modules 108 of each array 700 can be controlled and cycled in relative coordination to fully charge all of the arrays 700 (e.g., the array 700-PA module is charged to one or a few percent, then the array 700-PB module is charged to one or a few percent, then the array 700-PC module is charged to one or a few percent, and the process can be repeated until all modules are fully charged). With single-phase AC charging, the switching can occur rapidly such that each array 700-PA-700-PC is charged once or more times during the positive half of the cycle, and charged again once or more times during the negative half of the cycle.
Exemplary embodiments for charging arrays in parallel using motor bypass

In some embodiments, it may be desirable to charge the arrays 700 in parallel, for example in embodiments where parallel arrays are used to generate higher currents, or in embodiments where there are more phase arrays 700 than AC charging signals. FIG. 14 is a block diagram depicting an exemplary embodiment of system 100 having two subsystems 1000-1 and 1000-2 arranged in a manner similar to the embodiment of FIG. 10C. Switch 1108 is configured as a SPDT switch, where each subsystem 1000-1 and 1000-2 powers a different motor 1100-1 and 1100-2. System 100 can be configured to be charged using DC, single-phase AC, and/or polyphase charging signals, depending on the configuration (or absence) of routing circuitry 1200. Circuitry 1200 is coupled to a polyphase line 1111 that splits to connect with switch assemblies 1250-1 and 1250-2 such that subsystems 1000-1 and 1000-2 are charged in parallel. For example, the currents input to arrays 700-PA and 700-PD can be used to charge those modules in parallel with the currents combined in module 108IC-1, and the same can occur with arrays 700-PB and 700-PE and modules 108IC-2 and arrays 700-PC and 700-PF and module 108IC-3. The routing circuitry in this embodiment can be configured according to the embodiment of Figures 12B-12D or otherwise.

Figure 15A is a block diagram depicting another exemplary embodiment of system 100 with two subsystems 1000 to supply two motors 1100. Here, switch 1108 is configured as a SPST switch in switch assemblies 1250-1 and 1250-2, which also include switches 1331-1 and 1331-2, respectively. Switches 1331-1 and 1331-2 are configured as electromechanical relays and are closed during charging and open again during operation. Routing circuitry 1200 can be configured according to the embodiments of Figures 12B-12D or otherwise.

Figure 15B is a block diagram depicting another exemplary embodiment of system 100 with two subsystems 1000 to supply two motors 1100. Switch 1108 is again configured as a SPST switch in switch assemblies 1250-1 and 1250-2, but switches 1331-1 and 1331-2 are positioned in routing circuitry 1200 as described with respect to Figures 15C-15D. Figures 15C and 15D are schematic diagrams depicting routing circuitry 1200 configured similarly to Figures 13B and 13C, respectively, but with three-phase lines 1111 splitting to feed separate groups of switches 1331-1 and 1331-2. Routing circuitry 1200 can also be configured according to the embodiment of Figure 12B for DC and multi-phase charging on the right side of the split.

The embodiments of Figures 15A-15B can also be implemented with switch 1331 configured as an SSR device such as a triac or the like. Figure 15E is a block diagram depicting an example embodiment similar to that of Figure 15A but with switches 1331-1 and 1331-2 configured as triacs. Routing circuitry 1200 can be configured according to the embodiments of Figures 12B-12D or otherwise. In the embodiments of Figures 15A, 15B, and 15E, routing circuitry 1200 and connector 1202 can be omitted if it is desired to only have the capability for multi-phase charging.

Figure 15F is a block diagram depicting an example embodiment similar to that of Figure 15B, but with switches 1331-1 and 1331-2 configured as triacs. Figures 15G and 15H are schematic diagrams depicting example embodiments of routing circuitry 1200 for operating with the embodiment of Figure 15F. The embodiments of Figures 15G and 15H are similar to those of Figures 15C and 15D, respectively, but with separate groups of switches 1331-1 and 1331-2 implemented as triacs. Routing circuitry 1200 can also be configured according to the embodiment of Figure 12B, for DC and multi-phase charging on the right side of the split.

Figures 15H-15I are schematic diagrams depicting additional exemplary embodiments of routing circuitry 1200 configured for use with the embodiment of Figure 15B. In Figure 15H, the triac arrangement of Figure 12C is coupled to three-phase line 1111 at nodes X, Y, and Z. Three triacs TR5, TR6, and TR7 are positioned on lines 1111-PA, 1111-PB, and 1111-PC between nodes X, Y, Z and connector 1102. Line 1111 splits to form a second group of lines 1111-PD, 1111-PE, and 1111-PF having triacs TR8, TR9, TR10 positioned thereon. During motor operation or DC or single-phase AC charging, connector 1102 can be isolated by opening triacs TR5-TR7. During motor operation, the two groups of wires 1111 can be disconnected by opening triacs TR8-TR10. During multi-phase charging, triacs TR5-TR10 are closed and triacs TR1-TR4 are open. During DC and single-phase AC charging, triacs TR8-TR10 are closed.

Figure 15I depicts another exemplary embodiment in which the number of components from the embodiment of Figure 15H has been reduced by consolidation and reconfiguration while maintaining similar functionality. This embodiment has an SSR configuration 1510 similar to that of Figure 13H. As with the embodiment of Figure 15H, lines 1111-PD, 1111-PE, and 1111-PF cause triacs TR8-TR10 to disconnect the parallel connection during motor operation.

Figures 15J-15K are schematic diagrams depicting additional exemplary embodiments of routing circuitry 1200 configured for use with the embodiment of Figure 15B. In Figure 15J, the triac arrangement of Figure 12D is coupled to three-phase line 1111 at nodes X, Y, and Z. Three triacs TR5, TR6, and TR7 are positioned on lines 1111-PA, 1111-PB, and 1111-PC between nodes X, Y, Z and connector 1102. Line 1111 splits to form a second group of lines 1111-PD, 1111-PE, and 1111-PF, having triacs TR8, TR9, TR10 positioned thereon. During motor operation or DC or single-phase AC charging, connector 1102 can be isolated by opening triacs TR5-TR7. During motor operation, the two groups of wires 1111 can be disconnected by opening triacs TR8-TR10. During multi-phase charging, triacs TR5-TR10 are closed and thyristors T1-T4 are open. During DC and single-phase AC charging, triacs TR8-TR10 are closed.

FIG. 15K depicts another exemplary embodiment in which the number of components from the embodiment of FIG. 15J has been reduced by consolidation and reconfiguration while maintaining similar functionality. This embodiment has the SSR configuration 1334 of FIG. 13F. Diode configuration 1242 is connected between configuration 1334 and connector 1102, which acts as both a multi-phase and DC charging connector. As with the embodiment of FIG. 15H, lines 1111-PD, 1111-PE, and 1111-PF have triacs TR8-TR10 to disconnect the parallel connection during motor operation. During motor operation, connectors 1102 and 1202 can be isolated by opening triacs TR1-TR3. During motor operation, the two groups of lines 1111 can be disconnected by opening triacs TR8-TR10. During multi-phase charging, triacs TR1-TR3 and TR8-TR10 are closed and thyristors T1-T2 are open. During DC and single-phase AC charging, triacs TR8-TR10 are closed and configuration 1334 is operated similarly to that described with respect to FIG. 13F.

The system 100 has a highly scalable and adaptable configuration that allows for many different implementations for power applications with a wide range of voltage requirements and amounts of loads. The voltage requirements can vary from low-voltage applications on the scale of hundreds of watts (e.g., electric scooters, etc.) to high-voltage industrial applications on the scale of several megawatts and higher (e.g., power grids, nuclear fusion research, etc.). The number of loads can also vary, and the loads can be supplied by subsystems 1000 interconnected by one or more module 108 ICs under the control of a common control system 102. Alternatively, each subsystem 1000 can be under the control of a separate control system 102, with each control system 102 directly interfacing with a controller for a motor. The scalability and adaptability of the system 100 applies to both stationary and mobile applications. For ease of illustration, many of the following embodiments are again described with respect to mobile applications, in particular, but not limited to, various embodiments of an automobile EV.

The exemplary embodiment can be used with a conventional automobile EV having a single motor and one or more associated subsystems 1000 (e.g., battery pack). The exemplary embodiment can also be used with an automobile EV having two or more motors associated with a single subsystem 1000, or two or more motors each having one or more subsystems 1000 associated with it. The motors can be conventional motors mounted in the vehicle body that transfer power to the wheels with a powertrain or drivetrain. The motors can alternatively be in-wheel motors that directly power the wheel motion without a powertrain (or drivetrain). The EV may have an in-wheel motor for each wheel on the vehicle (e.g., 2, 3, 4, 5, 6, or more), or may have in-wheel motors for only some of the wheels on the vehicle. When multiple motors are present, a combination of approaches can be used, for example, in-wheel motors for the front wheels of the EV and conventional in-body motors and powertrains for the rear wheels, or vice versa.

The present subject matter provides the ability for different subsystems 1000 to provide power for motors with different voltage requirements. For example, a single four-wheel EV can have a first motor to power the front wheels and a second motor to power the rear wheels. The first motor may operate at a different voltage than the rear motor. Alternatively, the EV may have one motor per front wheel and one motor for both rear wheels, with the motors for the front wheels having different voltage requirements than the motors for the rear wheels. Or the EV may have one motor for the front wheels and two motors for the rear wheels, with the rear motors having different voltage requirements than the front motors. Still further, each wheel can have its own motor, with the front motors having voltage requirements that are different from the voltage requirements of the rear motors. Such variable combinations also apply to multi-motor EVs with two, three, five, six, or more wheels.

A motor having a relatively low voltage requirement, e.g., 300-400V nominal line peak voltage, may have a subsystem 1000 with relatively fewer modules than a higher voltage application. Alternatively or in addition, each module may have a lower nominal voltage than that of a higher voltage application. For example, a motor having a low voltage requirement, e.g., a relatively medium voltage requirement, higher than 400-700V nominal line peak voltage, may have a subsystem 1000 with relatively more modules per array than a low voltage subsystem 1000, and/or those modules may have the same or higher nominal voltage as that of the low voltage application. As a further example, a motor having a relatively high voltage requirement, e.g., higher than 700-800V nominal line peak voltage, may have a subsystem 1000 with relatively more modules per array than a low voltage and medium voltage subsystem 1000, and/or the nominal voltage of those modules may be relatively higher than that of the low voltage or medium voltage subsystem 1000. Of course, all subsystems 1000 can be configured with the same number of modules and only the nominal voltage of the modules can vary, or all subsystems 1000 can be configured with modules having the same nominal voltage but with a different number of modules per array.

The present subject matter also provides the ability to use energy sources having different types (e.g., different electrochemical properties, different physical structures, etc.). For example, one or more first subsystems 1000 in a multi-motor EV may have modules 108 with batteries of a first type, and one or more second subsystems 1000 in the multi-motor EV may have modules 108 with batteries of a second type. If interconnection modules 108IC are present, those modules 108IC can have batteries of a third type, different from the first and second types. If one or more subsystems have modules 108B with multiple energy sources per module, (a) one or more first subsystems have multiple energy sources per module and one or more second subsystems have only one energy source per module; (b) one or more first subsystems have multiple energy sources per module including a first type of primary energy source and a second type of secondary energy source and one or more second subsystems have multiple energy sources per module including the same first type of primary energy source and a third type of secondary energy source different from the first and second types; (c) one or more first subsystems have multiple energy sources per module including a first type of primary energy source and a second type of secondary energy source different from the first and second types; , (a) one or more first subsystems have multiple energy sources per module including a primary energy source of a first type and a secondary energy source of a second type, and one or more second subsystems have multiple energy sources per module including a primary energy source of a third type different from the first and second types and a secondary energy source of the same second type; or (b) one or more first subsystems have multiple energy sources per module and one or more second subsystems have multiple energy sources per module, and the type of energy source in the one or more first subsystems is different from the type of energy source in the one or more second subsystems. Still further combinations can be practiced, such as combinations such as:

Energy sources of different types can be manifested in terms of their operating characteristics. For example, different types of battery energy sources may have different nominal voltages, different C-rates, different energy densities, different capacities, each varying over temperature, state of charge, or usage (e.g., number of cycles). Examples of battery types include solid-state batteries, liquid electrolyte-based batteries, liquid-phase batteries, and flow batteries, such as lithium (Li) metal batteries, lithium-ion batteries, lithium-air batteries, sodium-ion batteries, potassium-ion batteries, magnesium-ion batteries, alkaline batteries, nickel-metal hydride batteries, nickel sulfate batteries, lead-acid batteries, zinc-air batteries, and others. Some examples of lithium-ion battery types include lithium cobalt oxide (LCO), lithium manganese oxide (LMO), lithium nickel manganese cobalt oxide (NMC), lithium iron phosphate (LFP), lithium nickel cobalt aluminum oxide (NCA), and lithium titanate (LTO).

The present subject matter provides the ability for different modules 108, subsystems 1000, and systems 100 to have different types of energy sources, particularly different types of batteries. One or more first subsystems in an EV can each include a module having a first type of energy source, and one or more second subsystems in an EV can each include a module having a second type of energy source different from the first type, the two types differing with respect to at least two operational characteristics. The first type of battery may have a first operational characteristic (e.g., nominal voltage, C-rate, energy density, or capacity) that is relatively greater than the same first operational characteristic of a different second type of battery, and the second type of battery may have a different second operational characteristic (e.g., nominal voltage, C-rate, energy density, or capacity) that is relatively greater than the same second operational characteristic of the first type of battery. For example, an EV may have a first type of energy source and a second type of energy source, where the first type (e.g., LFP) provides a relatively high C-rate and a relatively low energy density (or capacity), thus making it more suitable for acceleration performance, while the second type (e.g., NMC) provides a relatively low C-rate and a relatively high energy density (or capacity), thus making it more suitable for highway driving.

Thus, battery types can be mixed to achieve superior performance across different operating characteristics. The utilization of different types can be implemented within a single module (e.g., a first type of primary source 206A and a second type of secondary source 206B), between different modules of the same single subsystem 1000 or system 100 (e.g., one or more modules 108 having a first type of energy source 206 and one or more modules 108 having a second type of energy source 206), and/or between subsystems 1000 or systems 100 (e.g., a first subsystem having modules each having a first type of energy source and a second subsystem having modules each having a second type of energy source).

These variations in voltage capabilities (e.g., low, medium, high) and energy source types can be applied to all embodiments described herein. These variations are particularly applicable to embodiments having two or more separate subsystems 1000 for powering multiple motors 1100, such as those described with respect to Figures 10C, 14, 15A, 15B, 15E, and 16A-18B. When charging subsystems with different voltage capabilities, each subsystem can be charged independently with a dedicated charging port and charging cable (from a dedicated or shared charging source), or the subsystems can be charged in parallel from its same charging cable and connector, such as the parallel configuration described with respect to Figures 14, 15A, 15B, and 15E (and elsewhere). When charging any of the embodiments described herein, if it is desired to maintain sufficient tolerance to perform balancing during the charging process, it is preferred that the available charging source voltage (e.g., peak line voltage for AC charging) be less than the sum of the current voltages of the sources 206 being charged at any one time.

16A is a block diagram depicting an exemplary embodiment of system 100 having three subsystems 1000-1, 1000-2, 1000-3 for powering three motors 1100-1, 1100-2, and 1100-3, respectively. In this example, motors 1100-1 and 1100-2 are each associated with different front wheels of a four-wheel EV and have a moderate voltage requirement, while motor 1100-3 is associated with two rear wheels of the EV and has a relatively higher voltage requirement than motors 1100-1 and 1100-2. Arrays 700 of subsystems 1000-1 and 1000-2 each may have N modules 108 as shown, with the value of N for the two subsystems preferably being the same. Arrays 700 of subsystems 1000-3 each may have M modules 108, which may be any integer number equal to or greater than 2. The array 700 of subsystem 1000-3 is configured to produce a relatively larger voltage than the arrays 700 of subsystems 1000-1 and 1000-2, and thus subsystem 1000-3 will often have more modules 108 than subsystems 1000-1 and 1000-2. In certain other embodiments, the number of modules may be consistent between subsystems, for example, if each module 108 of subsystem 1000-3 is capable of generating a larger voltage than the modules 108 of subsystems 1000-1 and 1000-2, such as by use of a battery type having a higher nominal voltage, or by inclusion of multiple energy sources 206 within each module 108 of subsystem 1000-3.

There are three interconnection modules 108IC-1, 108IC-2, and 108IC-3, each including three switch portions 604 for connection to three different arrays 700. Each module 108IC is coupled to the three arrays 700 of a single subsystem, with module 108IC-1 coupled to arrays 700-PA, PB, PC of subsystem 1000-1, module 108IC-2 coupled to arrays 700-PD, PE, PF of subsystem 1000-2, and module 108IC-3 coupled to arrays 700-PG, PH, PI of subsystem 1000-3. In this embodiment, each subsystem 1000 may be under the control of a separate control system 102 that interfaces with that subsystem's associated motor 1100. The modules 108IC are interconnected to provide power for the auxiliary loads 301 and 302.

In an alternative embodiment, each module 108IC may be coupled to at least two different subsystems 1000. For example, module 108IC-1 may be coupled to arrays 700-PA and 700-PB of subsystem 1000-1 and array 700-PG of subsystem 1000-3. Module 108IC-2 may be coupled to arrays 700-PC of subsystem 1000-1, array 700-PD of subsystem 1000-2, and array 700-PH of subsystem 1000-3. Module 108IC-3 may be coupled to arrays 700-PE and 700-PF of subsystem 1000-2 and array 700-PI of subsystem 1000-3. In this alternative embodiment, the subsystems 1000 may be under the control of a common control system 102 that interfaces with controllers for all three motors 1100 and also collects status information for each subsystem 1000, and is configured to perform inter-array balancing between the subsystems 1000.

In FIG. 16A, line 1111-1 connects with switch 1108 in switch assembly 1250-1. An additional set of switches 1602 is included on line 1111-1 between subsystems 1000-1 and 1000-2. These switches 1602 can be SPDT switches (either electromechanical relays or SSRs) that default to an open state so that motors 1100-1 and 1100-2 are disconnected during operation. Switches 1602 can be closed to charge under control of associated system 102. Control lines are not shown. Switches 1108 are SPDT switches and the parallel charging approach described with respect to FIG. 14 can be used to charge these embodiments.

16B is a block diagram depicting another exemplary embodiment of a three-motor topology in which motors 1100-1 and 1100-2 are configured for multi-phase charging from a first charging connector 1102-1 and motor 1100-3 is configured for multi-phase charging from a second charging connector 1102-2. In this embodiment, different multi-phase charging voltages can be applied to each connector such that relatively high voltage subsystem 1000-3 can be charged using a higher voltage charging signal than the relatively lower voltage subsystems 1000-1 and 1000-2.

FIG. 16C is a block diagram depicting another example embodiment in which a single charging connector 1102 may be used, a high voltage multi-phase charging signal may be passed directly to subsystem 1000-3 via lines 1604, and a lower voltage AC charging signal may be produced by a three-phase transformer 1610 and fed to subsystems 1000-1 and 1000-2 via lines 1606.

Each of the embodiments of Figures 16A-16C can be configured as a four motor system 100. Figure 17 is a block diagram depicting an exemplary embodiment of system 100 having four motors 1100, each with an associated subsystem 100. In this embodiment, subsystem 1000-1 has three IC modules 108IC-1 through 108IC-3, and subsystem 1000-2 has three IC modules 108IC-4 through 108IC-6. Each module 108IC-1 through 108IC-3 has two switch portions 604 (not shown) for connecting to the arrays 700 of subsystem 1000-1 and the arrays 700 of subsystem 1000-3, and each module 108IC-4 through 108IC-6 has two switch portions 604 (not shown) for connecting to the arrays 700 of subsystem 1000-2 and the arrays 700 of subsystem 1000-4. This embodiment can be implemented under the control of a single control system 102 (not shown) configured to implement balancing between and within the subsystems 1000. Alternatively, this four-motor embodiment can be implemented with one (as in the embodiment of FIG. 16A), two, or three IC modules 108 IC per subsystem 1000 to implement phase-to-phase balancing within each subsystem. Although the subsystems 1000 are each shown as having N modules, the number of modules per subsystem can vary. Two switches 1108 are used per motor 1100.

The charging configuration for this embodiment is similar to that of the three motor embodiment, but with an additional set of switches 1602-2 located between subsystems 1000-3 and 1000-4. These switches 1602-2 can be SPST switches (e.g., electromechanical relays or SSRs) that default to an open position and are closed during charging under the control of the control subsystem 102.

18A-18B are block diagrams depicting an exemplary embodiment of system 100 configured to supply three-phase power to an EV having six motors. The six-motor configuration can be used with EVs having a single chassis or multiple chassis movably connected together. For example, the front chassis can have two motors and the rear chassis can have four motors, or the front chassis can have four motors and the rear chassis can have two motors. Using the electrical configuration depicted here, motors 1100-1 and 1100-2 can be front wheel motors, motors 1100-3 and 1100-4 can be mid-wheel motors, and motors 1100-5 and 1100-6 can be rear wheel motors. Alternatively, motors 1100-1 and 1100-3 can be front wheel motors, motors 1100-2 and 1100-4 can be mid-wheel motors, and motors 1100-5 and 1100-6 can be rear wheel motors.

The charging configuration for this embodiment is similar to that of the four motor embodiment, but with an additional split in the wires 1111, such that a third set of wires 1111-3 carries a polyphase charging signal to the motors 1100-5 and 1100-6. The additional switch assembly 1250-3 may have a set of two additional switches 1602-3 and 1602-4 located between the subsystems 1000-5 and 1000-6. These switches 1602-3 and 1602-4 may be SPST switches (e.g., electromechanical relays or SSRs) that default to an open position and are closed during charging under the control of the control subsystem 102. The switches 1602-3 and 1602-4 may disconnect the system 1000-5 from the system 1000-6 and also provide isolation from the charging connectors 1102 and 1202. If charging connector isolation is provided in routing network 1200, switches 1602-3 and 1602-4 may be aggregated as one switch set.

In the embodiments of Figures 16A-16C, 17, and 18, switch 1108 can alternatively be configured as a SPST switch as described herein, and the parallel charging approach described with respect to Figures 15A-15K can be used to charge. The split in line 1111 can occur outside of routing circuitry 1200, as shown in these embodiments, or within routing circuitry 1200, as in the embodiments of Figures 15B-15D and 15F-15K. As with the embodiments of Figures 14-15K, the embodiments of Figures 16A-16C, 17, and 18 can be configured for only multi-phase charging, only single-phase charging, only DC charging, all three types of charging, or any combination thereof. The array 700 can be charged in parallel during all three types of charging.

System 100 can also be configured to charge arrays 700 in parallel in a configuration that powers only one motor. Figures 19A-19B are block diagrams depicting an exemplary embodiment of a six-phase system 100 configured to supply power to a six-phase motor 1900. System 100 includes arrays 700 corresponding to each of the six phases PA, PB, PC, PA', PB', and PC'. A three-phase charging connector 1102 is connected to system 100 such that arrays 700-PA and 700-PA' can be charged in parallel, arrays 700-PB and 700-PB' can be charged in parallel, and arrays 700-PC and 700-PC' can be charged in parallel. Lines from connector 1102 branch into a first set of lines 1911 and a second set of lines 1912. The PA line of the connector 1102 is connected via one of the lines 1911 to the PA port of the motor 1900 and to I/O port 1 of the module 108-1 of the array 700-PA, and the PA line of the connector 1102 is connected via one of the lines 1912 to the PA' port of the motor 1900 and to I/O port 1 of the module 108-1 of the array 700-PA'. The PB line of the connector 1102 is connected via another line 1911 to the PB port of the motor 1900 and to I/O port 1 of the module 108-1 of the array 700-PB, and the PB line of the connector 1102 is connected via another line 1912 to the PB' port of the motor 1900 and to I/O port 1 of the module 108-1 of the array 700-PB'. The PC line of connector 1102 is connected via another line 1911 to the PC port of motor 1900 and to I/O port 1 of module 108-1 of array 700-PC, and the PC line of connector 1102 is connected via a final line 1912 to the PC' port of motor 1900 and to I/O port 1 of module 108-1 of array 700-PC'.

Switches 1908-1, 1908-2, and 1908-3 are connected in series in line 1912 to selectively connect and disconnect the connection made by line 1912. Switch 1908 preferably defaults to an open position for operation of motor 1900 while system 100 is in a discharging state. When system 100 enters a charging state, switch 1908 is closed, bypassing motor 1900 and allowing charging of the various arrays 700 in parallel. Switch 1908 can be configured as an electromechanical or solid state switch as described elsewhere herein. Alternatively, six switches can be installed at each of the six ports (PA-PC') of motor 1900 to bypass motor 1900 during charging.

The embodiment of Figure 19A is similar to that described with respect to Figures 11A-11B, but can be charged using a three-phase charging signal through a three-phase connector 1902 in a manner where each array pair is charged in parallel. Current can be routed through the modules 108 IC as described herein and used to charge the sources of the modules 108 IC. The charging process can occur while voltage is still being supplied to the auxiliary loads 301 and 302. The voltage, current, and/or phase can be measured by a monitor device 1310 as described herein, and the various modules 108 can be switched to target a power factor of unity or within a threshold of unity (e.g., 1%, 2%, 5%).

The embodiment of Figure 19B includes routing circuitry 1200 as described with respect to Figures 12C-12D and can be charged using three types of charging: DC, single-phase AC, or three-phase AC. For example, the configuration of routing circuitry 1200 that applies charge connector isolation for parallel charging as described with respect to Figures 15C, 15D, and 15F-15K can be adapted for use in this embodiment having a six-phase motor as well. Switch 1908 is closed during all three types of charging and is open during normal operation of system 100 in a discharging state to power motor 1900. Array 700 is again charged in parallel during all three types of charging.
Exemplary embodiment for charging the array through the motor

System 100 can also be configured to charge array 700 through the motor so that adaptive routing circuitry 1200 is not needed. Figure 20 is a block diagram depicting an exemplary embodiment of system 100 similar to that of Figure 11A but with dual DC and single phase AC charging connectors 2002 that may be integrated with three phase charging connector 1102 in a single user accessible location or separate therefrom and in different locations on the EV. Dual connector 2002 is connected to a first wire 2004-1, which in turn is connected to a phase port of motor 1100, which in this embodiment is PC and switch 1108-PC. Connector 2002 is connected to a second wire 2004-2, which may be connected to system output port SIO4 of system 100. This system output port SIO4 can be module output port 2 of interconnect module 108IC-2, which is connected to array 700-PC, or output port 2 of module 108-N of array 700-PC if no IC module is present. Connector 2002 can be connected to positive and negative DC conductors for DC charging, or to AC line and AC neutral conductors for single phase AC charging, which in this example are connected to lines 2004-1 and 2004-2, respectively. Other connections can also be implemented.

DC charging can be performed such that one, two, or all three arrays 700 are charged simultaneously. Single-phase AC charging can also be performed such that one, two, or all three arrays 700 are charged simultaneously. DC and AC charging can be performed in a manner that seeks to balance the temperature differences between the modules 108 as described herein and reaches a balanced SOC across all modules 108 as described herein. AC charging is performed to maintain a power factor at or near unity. In all cases, if a measurable current passes through the motor coils or windings and flux is generated, the sensors of the system 100 will detect this current and the control system 102 will control the switching of each module 108 such that the magnitude and phase of all fluxes through all windings cancel or neutralize each other, or substantially cancel or neutralize each other, and any fluctuations in flux are below a threshold and insufficient to turn the motor.
Series DC charging of each array

To charge array 700-PA, switch 1108-PA is placed in position 1, connecting array 700-PA to motor 1100. Switches 1108-PB and 1108-PC are placed or held in position 2. In response to application of a DC charging voltage, current enters the DC+ port of connector 2002, passes through line 2004-1 to motor 1100, where it passes through the motor's PC and PA windings. Current exits motor 1100, passes through switch 1108-PA and monitor circuitry 1110-PA, through array 700-PA, and each module 108-1 through 108-N can be individually charged by switching individual converters 202 in accordance with the techniques described herein. Charging current for modules 108IC-1 and 108IC-2 passes through S7 of switch portion 604-PA, charging source 206 of modules 108IC-1 and 108IC-2 (in parallel as shown in FIG. 10E), and can exit module 108IC-2 through module I/O port 2, which may be placed along the rail (the IO port 6 node) or between S7 and S8 of additional switch portion 604 as shown in FIG. 10E. The current then exits system 100 through the DC/ port of connector 2002.

To charge array 700-PB, switch 1108-PB is placed in position 1, connecting array 700-PB to motor 1100. Switches 1108-PA and 1108-PC are placed or held in position 2. Current passes from the DC+ port of connector 2002, through line 2004-1, to motor 1100, and then through the motor's PC and PB windings. Current then passes through switch 1108-PB and monitor circuitry 1110-PB, through array 700-PB, and each module 108-1 through 108-N can be individually charged by switching individual converters 202 according to the techniques described herein. Charging current for modules 108IC-1 and 108IC-2 can pass through S7 of switch portion 604-PB, through charging sources 206 of modules 108IC-1 and 108IC-2 (in parallel as shown in FIG. 10E), exit module 108IC-2 through module I/O port 2, and exit system 100 through the DC- port of connector 2002.

To charge array 700-PC, switch 1108-PC is placed in position 1, connecting array 700-PC to line 2004-1. Switches 1108-PA and 1108-PB are placed or held in position 2. Current passes from the DC+ port of connector 2002, through line 2004-1, bypassing motor 1100, through switch 1108-PC and monitor circuitry 1110-PC, through array 700-PC, and each module 108-1 through 108-N can be individually charged by switching individual converters 202 in accordance with the techniques described herein. Charging current for modules 108IC-1 and 108IC-2 can pass through S7 of switch portion 604-PC, through charging sources 206 of modules 108IC-1 and 108IC-2 (in parallel as shown in FIG. 10E), exit module 108IC-2 through module I/O port 2, and exit system 100 through the DC-port of connector 2002. To shut down charging source 206 of a module 108IC, S8 of the associated switch portion 604 can be activated to direct current directly to port 2 of module 108IC-2.
Parallel DC Charging of Two or More Arrays

To charge two or more of the arrays 700 in parallel using a DC charging signal provided to the connector 2002, the switch 1108 connected to the array 700 to be charged is then placed or held in position 1, and the switch 1108 connected to any array 700 not being charged is placed or held in position 2. To shut down the charging source 206 of the module 108 IC, S8 of each switch portion 604 of the charged array 700 can then be activated, or the switch portion 604 of the array 700 being charged can be modulated at a 50-50 duty cycle. The current through the array 700 being charged is regulated by the module 108 to maintain a countervailing flux through the motor 1100 and charge the module's energy source 206 while balancing the module (e.g., temperature and SOC).
Parallel single-phase AC charging of all arrays

Switch 1108 is then placed or held in position 1 to charge all of arrays 700 in parallel with the single phase AC signal provided to connector 2002. Current from line 2004-1 is supplied to array 700-PA through the PC and PA windings of motor 1100, to array 700-PB through the PC and PB windings of motor 1100, and directly from line 2004-1 to array 700-PC (bypassing motor 1100). The current then passes through arrays 700-PA, 700-PB, and 700-PC and each of modules 108IC-1 and 108-IC2, and exits through I/O port 2 of module 108IC-2. The current through array 700 is regulated by module 108 to maintain a canceling flux through motor 1100, such as by making the current through windings PA and PB equal that through winding PC with all currents in phase, thus neutralizing the flux. Energy source 206 of module 108 can be charged while balancing one or more operating characteristics (e.g., temperature and SOC) of module 108 according to the techniques described herein.
Parallel single-phase AC charging of each array or a subset of arrays

To charge one or a subset of the arrays 700 in parallel with the single-phase AC signal provided to connector 2002, then the switch 1108 corresponding to the array 700 being charged is placed or held in position 1 and the other switch is placed or held in position 2. Current from line 2004-1 is either supplied to the array 700 being charged through the windings of the motor 1100, or bypasses the motor 1100 if array 700-PC is being charged. The current then passes through the array 700 being charged and modules 108IC-1 and 108-IC2, and exits through I/O port 2 of module 108IC-2. The current through the array 700 being charged is regulated by module 108 to maintain a canceling flux through the motor 1100, which is relatively simple when only two windings (PC and PA or PC and PB) are used. The energy source 206 of the module 108 can be charged while balancing one or more operating characteristics (eg, temperature and SOC) of the module 108 in accordance with the techniques described herein.

In the above-described embodiment of the charging system 100, both when bypassing the motor 1100 and when charging through the motor 1100, the switches 1108 are switched to a position that allows current flow through one or more arrays that are being charged and prevents current flow through any arrays that are not being charged. Alternatively, all of the switches 1108 can be placed in a position that allows charging, and current flow through an array that is not being charged can be regulated or prevented using the modules 108 of that array 700 and any module 108 ICs coupled to that array 700. Some current flow through an array 700 that is not being charged may be desired to help neutralize flux in the motor.
Delta and Series Topology Charging

The subject charging described herein can be used with topologies having delta and series arrangements of modules 108 similar to those described with respect to Figures 7D and 7E. Figure 21A is a block diagram depicting an example embodiment of system 100 with a delta and series arrangement similar to that of Figure 7E, but with the addition of interconnection modules 108IC-1 and 108IC-2 supplying auxiliary loads 301 and 302. This embodiment is configured for three-phase charging through connector 1102, or DC or single-phase AC charging through connector 2002. Three-phase charging can occur directly from the three-phase charging connector 1102. For DC and single phase AC charging, arrays 700-PA, 700-PB, and 700-PC are interconnected by lines 2104 so that DC+ and AC(L) current from line 2104-1 can be input directly to module 108-1 of array 700-PC and module 108-(M+1) of array 700-PB, and circulated from there to the rest of the modules 108 of system 100. Current from DC and single phase AC charging can exit via module 108IC-2 and line 2104-2.

21B is a block diagram depicting another example embodiment of system 100 having a similar arrangement to that of FIG. 21A but with routing circuitry 1200 coupled between dual charging connectors 1202 and three-phase charging line 1111. This delta and series topology can be charged using either a three-phase, single-phase, or DC charging source, as described elsewhere herein.
Charging an Open Winding Load

The charging subject matter described herein can be used with a topology having multiple subsystems 1000 providing power for one or more open winding (or coil) loads. FIG. 22 is a block diagram depicting an exemplary embodiment of system 100 having subsystems 1000-1 and 1000-2 for supplying an open winding motor 2200. Subsystem 1000-1 initially includes arrays 700-PA, 700-PB, and 700-PC, which supply power to a first port of motor 2200, having phases PA, PB, and PC, respectively. Subsystem 1000-2 initially includes arrays 700-PA', 700-PB', and 700-PC', which supply power to a second port of motor 2200, having phases PA', PB', and PC', respectively. Subsystem 1000-2 also includes modules 108IC-1 and 108IC-2 for phase-to-phase balancing and supply of loads 301 and 302.

The three phase charging connector 1102 is coupled to I/O port 1 of module 108-1 of arrays 700-PA, 700-PB, and 700-PC. The switch 2208-1 is connected between I/O port 1 of module 108-1 of array 700-PA and I/O port 1 of module 108-1 of array 700-PB. The switch 2208-2 is connected between I/O port 1 of module 108-1 of array 700-PB and I/O port 1 of module 108-1 of array 700-PC. The three phase charging connector 1102 can be used to supply three phase power for charging both subsystems 1000-1 and 1000-2 when the switches 2208-1 and 2208-2 are in the open position.

Dual DC and single phase AC charging connector 2202 has a DC+ or AC(L) line 2204-1 that is connected to I/O port 1 of module 108-1 of array 700-PC, and a DC- or AC(N) line 2204-2 that is connected to I/O port 2 of module 108IC-2. Dual charging connector 2202 can be used for DC or single phase AC charging when a three phase charging source is not connected and switches 2208-1 and 2208-2 are in the closed position.

As with other embodiments described herein, with the use of monitor circuitry 1110, charging is performed under the control of control system 102 to maintain fluxes in motor 2200 that cancel each other out and prevent the motor from spinning. Charging is also performed in a manner that targets an equilibrium condition of one or more operating characteristics (e.g., SOC or temperature) of each module 108 of system 100. For three-phase charging, current will pass from one or two signals from the charging source that are positive to the remaining negative signal of the charging source. For example, if phase PA is positive and phases PB and PC are negative, current will pass through array 700-PA, then through the PA-PA' windings of motor 2200, then through array 700-PA' and module 108IC-1. From there, the current can pass back through one of two paths, either through array 700-PB', winding PB-PB', and array 700-PB, or through module 108IC-2, array 700-PC', winding PC-PC', and array 700-PC, and then out through connector 1102. As current passes through each array 700 of subsystem 1000, regardless of the direction of the current, each module 108 can be selectively charged according to the techniques described herein. Single phase AC and DC charging can be performed in parallel along each of the three current paths, with each module 108 switching as needed to charge in a balanced manner; the three current paths are: (1) array 700-PA, windings PA-PA', array 700-PA', and module 108IC-1; (2) array 700-PB, windings PB-PB', array 700-PB', and module 108IC-1; and (3) array 700-PC, windings PC-PC', array 700-PC', and module 108IC-2.
Exemplary embodiments of the charger

System 100 can also be used as a charging source 150 for charging electric vehicles or other loads. FIG. 23A is a block diagram depicting an exemplary embodiment of a first instance of system 100 (referred to herein as system 100-1) configured as a buffer in charging station 150. System 100-1 can be charged using energy from an external power provider or a local power grid, and then fast charge EV 2300 using charging cable 2302. The EV can have a conventional battery pack or can have a battery pack configured with a second instance of system 100 (referred to herein as system 100-2). Fast charging of EV 2300 can be implemented using a DC charging signal, a single-phase AC charging signal, or a poly-phase AC charging signal, depending on the configuration of systems 100-1 and 100-2. Charging from the power grid can occur at a relatively lower voltage and slower rate than the relatively higher voltage and faster charging rate implemented via cable 2302. Additionally, the buffer system 100-1 may be continuously charged while fast charging one or more EVs 2300. Depending on the size of the sources 206 in the buffer system 100-1, the system 100-1 may have the capacity to charge multiple EVs before requiring recharging from the utility grid. In other embodiments, the charging station 150 can be coupled to a renewable energy source, such as an array of solar panels, wind, or other renewable sources, such that a utility grid connection may be omitted.

23B is a schematic diagram depicting an exemplary embodiment similar to that of FIG. 23A, where the three-phase configuration of system 100-1 is used as an energy storage buffer in charging source 150. In this embodiment, charging source 150 is configured to provide a high-voltage three-phase charging signal to a first EV 2300 configured with a battery pack having system 100-2, and also to provide a high-voltage DC charging signal to a second EV 2350 having a conventional battery pack without modular switch capability. System 100-1 is a three-phase system with arrays 700-PA, 700-PB, and 700-PC connected to a three-phase power system 2360 using transformer 2362 and inductive interface network 2364. System 100-1 also includes an AC/DC converter and charging circuit 2366. System 100-1 can output three phase power to EV 2300 using interface circuitry 2364, inductive interface circuitry 2365, and charging cable 2370, and can output three phase power to EV 2350 using interface circuitry 2364, inductive interface circuitry 2367, and an AC/DC converter in charging circuit 2366 that converts the three phase power to a DC signal that is output via DC charging cable 2372.

In this embodiment, the system 100-1 can be slow charged from the power grid 2360 and store energy in the various module 108 sources for use in fast charging the EVs 2300 and 2350 using either a polyphase AC or DC approach. The charging source 150 can adjust the output voltage for different vehicles (e.g., low voltage and high voltage vehicles) by adjusting the output voltage produced by the array 700 of the system 100-1 according to PWM and other control techniques described herein. High voltage charging can be performed at high C rates, which can be as high as the EVs are rated to receive, for example, 2C to 12C and higher, based on the system and EV configuration. The charging station 150 can also be configured for high voltage single phase or DC charging, for example, by installation of the routing circuitry 1200 in the EV 2300 or charging station 150, or alternatively, by use of a transformer.

Charging source 150 can be configured to inject current to cancel harmonic components generated by AC/DC converter and charging circuit 2366. Harmonics generated by circuit 2366 or by other aspects of the charging of EVs 2300 and 2350 can be detected by monitor circuitry 2380, which can be configured to measure the current, voltage, and/or phase of signals passing from and to power grid 2360. Control system 102 (not shown) of system 100-1 can detect the harmonics and cause modules 108 of system 100-1 to produce compensating currents of opposite polarity to the harmonics but in phase with the harmonics to cancel the redirection of the harmonics into power grid 2360. This active filtering capability of system 100-1 can allow circuit 2366 to be implemented with higher harmonic content such as diodes, which significantly reduces the cost of circuit 2366 compared to similar circuits implemented with lower harmonic content such as IGBTs.
Exemplary Physical and Electrical System Layout Embodiments

The modular nature of the system 100 allows for greater flexibility in physical layout and orientation within an EV chassis. The module dimensions and aspect ratio in the horizontal plane are dictated primarily by the volume of the one or more energy sources 206 contained therein; the support circuitry is much smaller and can be located above or below the housing 220 for the one or more sources 206 (see, e.g., FIG. 2C). FIGS. 24-28C are schematic diagrams depicting example embodiments of layouts for various configurations of the system 100. The electrical connections on these figures are not shown in detail and are therefore fully explained elsewhere herein, with the emphasis here instead being placed on the physical arrangement.

FIG. 24 depicts an arrangement 2400 of systems 100 within interior region 180 at the base of an EV chassis, with systems 100 configured in three arrays to provide three-phase power to motor 1100. Here, there are ten stages of modules 108 in each array. The modules 108 in the phase PA array are modules 1A-10A, the modules 108 in the phase PB array are modules 1B-10B, and the modules 108 in the phase PC array are modules 1C-10C. System 100 also includes modules IC1, IC2, and ICAUX, arranged in an arrangement similar to that of FIG. 10F, with module ICAUX configured in an auxiliary role. In the horizontal plane of the EV, each module 108 has a generally rectangular profile, with the shorter dimension oriented along axis 2401 and the longer dimension oriented along axis 2402. The modules 108-2 through 108-10 of each array are aligned in columns, with each column parallel to axis 2401. The modules 108 of each stage 2-10 are aligned in rows, with each row parallel to axis 2402. Modules 108-1A, 1B, 1C are arranged in an alternating configuration occupying two rows, with modules 108-1A and 108-1C adjacent to one another, with module 108-1A overlapping a column for the PA and PB arrays, and module 108-1C overlapping a column for the PB and PC arrays. Module 108-1B is generally aligned in a column for phase PB, but with modules 108-1A and 108-1C interposed between module 108-1B and module 108-2B. A similar configuration exists on the opposite end of area 180 for module 108IC. This configuration, with its alternation and rows, allows the maximum amount of voltage carrying capacity to be compactly distributed within area 180, which in this example has an eight-sided configuration tapered at each end 181 and 182, and refers to the space within the EV chassis available for installation of energy system 100. The battery pack enclosure for system 100 can have the same shape and dimensions as area 180 in the horizontal plane. Array 2400 can be configured to implement charging according to any of the single motor embodiments described herein and can include switch 1108, switch assembly 1250, charging connector, and routing circuitry 1200.

FIG. 25A depicts an arrangement 2500 of another exemplary embodiment of system 100 configured with two subsystems 1000-1 and 1000-2 configured to supply three-phase power (PA-PC and PD-PF) for motors 1100-1 and 1100-2, respectively. In this example, each subsystem 1000 includes five rows of modules 108. The modules 108 are again oriented in the same manner, with the longer dimension of each module oriented along axis 2402 and the shorter dimension aligned along axis 2401. A row of IC modules 108 IC are positioned between the two subsystems 1000, which are arranged in a symmetrical opposed manner. The electrical connections of this embodiment may vary according to embodiments described herein. Here, the IC modules are shown connected in a manner similar to that of FIGS. 15A, 15B, and 15E. Each subsystem 1000 can be configured to supply different voltages based on the requirements of the two motors 1100. With subsystem 1000 oriented in a front and rear arrangement, motor 1100-1 can provide power to the drive train of the EV for the two front wheels, while motor 1100-2 can provide power to the drive train for the two rear wheels. Arrangement 2500 can be configured to implement charging according to any of the two-motor embodiments described herein and can include switch 1108, one or more switch assemblies 1250, a charging connector, and routing circuitry 1200.

25B depicts an arrangement 2550 of another exemplary embodiment of system 100 configured with two subsystems 1000-1 and 1000-2 configured to provide three-phase power for motors 1100-1 and 1100-2, respectively. In this example, each subsystem 1000 again includes five rows of modules 108, but the subsystems 1000 are oriented in a left-right arrangement, with the modules 108 instead oriented with their longer dimension along axis 2401 and their shorter dimension along axis 2402. A row of alternating IC modules 108 ICs are present at end 181, and their orientation is reversed such that the longer dimension of the modules 108 ICs is along axis 2402 and the shorter dimension of the modules 108 ICs is along axis 2401. The electrical connections between all of the modules 108 in this embodiment may vary according to embodiments described herein. In this embodiment, because the subsystems 1000 are positioned side-by-side along the axis 2402, the subsystems preferably have the same or similar voltage configuration. Because each wheel has a dedicated motor 1100, the voltages supplied to those motors 1100 can be relatively greater than that of the array 2500. The motors 1100-1 and 1100-2 can power the front or rear wheels. The switch assembly 1250 is positioned at the end 182 and is electrically connected between the subsystem 1000 and the motors 1100. The assembly 1250 can include switches 1108 for both motors 1100 (combined assemblies 1250-1 and 1250-2), as described with respect to FIGS. 14, 15A, 15B, and 15E. The array 2550 can be configured to implement charging according to any of the two-motor embodiments described herein and can include a charging connector and routing circuitry 1200.

26 depicts an arrangement 2600 of another exemplary embodiment of system 100 configured with three subsystems 1000-1, 1000-2, and 1000-3 configured to provide three-phase power for motors 1100-1, 1100-2, and 1100-3, respectively. Motors 1100-1 and 1100-2 are each dedicated to a separate wheel of the EV, and motor 1100-3 is dedicated to the drive train for two wheels. Motors 1100-1 and 1100-2 may power the front wheels and motor 1100-3 may power the rear wheels, or vice versa. In this example, subsystems 1000-1 and 1000-2 each include three stages and are arranged in a side-by-side (left and right) relationship, with each array aligned in a row along axis 2402 and each stage aligned in a column along axis 2401. A row aligned along axis 2401 and located between subsystems 1000-1 and 1000-2 includes three IC modules 108IC interconnecting all three subsystems 1000. The modules 108 of subsystems 1000-1 and 1000-2 are oriented in addition to the modules 108IC such that the longer dimension of each module is aligned along axis 2401 and the shorter dimension is aligned along axis 2402. Subsystem 1000-3 includes eight rows of modules 108, with each array aligned in a column and rows 2-8 aligned in rows, and in contrast to the orientation of subsystems 1000-1 and 1000-2, the longer dimension of each module is aligned along axis 2402 and the shorter dimension is aligned along axis 2401. The first row of modules 108 of subsystem 1000-3 is arranged in an alternating fashion at end 182. In this embodiment, the power provided by subsystem 1000-3 can exceed the power provided by subsystem 1000-1 or subsystem 1000-2. The electrical connections between all of the modules 108 in this embodiment can vary according to the embodiments described herein. The arrangement 2600 can be configured to implement charging according to any of the three-motor embodiments described herein and can include the switch 1108, the switch assembly 1250, the charging connector, and the routing circuitry 1200.

27A-27B depict arrays 2700 and 2750 of an exemplary embodiment of system 100 configured with four subsystems 1000-1, 1000-2, 1000-3, and 1000-4, respectively, configured to provide three-phase power for motors 1100-1, 1100-2, 1100-3, and 1100-4, respectively. Each motor 1100 is dedicated to a separate wheel of the EV. Each subsystem 1000 includes three stages of modules 108, with all or most of the stages aligned in columns along axis 2401, and each array aligned in rows along axis 2402. All of the modules 108 are oriented such that the longer dimension of each module is aligned along axis 2401 and the shorter dimension is aligned along axis 2402. In this embodiment, each subsystem 1000 is configured to generate the same voltage for its respective motor 1100, although in other embodiments the voltages produced by the various subsystems 1000 can be different. The electrical connections between all of the modules 108 in this embodiment can vary according to the embodiments described herein. The module 108 IC interconnects the four subsystems 1000, for example, as described with respect to FIG. 17. The assemblies 1250-1 and 1250-2 can be configured similar to the embodiment of FIG. 17 and the parallel charging subject matter described herein. The arrangement 2700 can be configured to charge according to any of the three motor embodiments described herein and can include a charging connector and routing circuitry 1200.

In array 2700, the column of IC modules is oriented along axis 2401 and is located in the center, with subsystems 1000-1 and 1000-3 on the left and subsystems 1000-2 and 1000-4 on the right. In array 2750, region 180 tapers into a columnar shape at both ends 181 and 182. The PC array of subsystem 1000-2 is located in this columnar region at end 181, and the PA array of subsystem 1000-3 (the diagonally opposite subsystem) is located in the columnar region at end 182, along with module 108IC-6. As an alternative to the embodiment of Figures 27A-27B, most or all of the columns can be aligned in rows along axis 2402 and most or all of the arrays can be aligned in columns along axis 2401, and modules 108IC can be aligned as shown here or as rows along axis 2403.

28A-28C depict exemplary embodiment arrangements 2800, 2820, and 2850 of system 100 configured with six subsystems 1000-1 to 1000-6, respectively, configured to provide three-phase power for motors 1100-1 to 1100-6, respectively. Each motor 1100 is dedicated to a separate wheel of the EV. In these embodiments, the EV includes a first chassis having a first energy system area 180 and a second chassis having a second energy system area 280. The two chassis are movable relative to each other in a mechanical and electrical connection 2801. The EV can be configured such that the first chassis is at the front and the second chassis is at the rear, or vice versa. These six-wheel configurations are suitable for larger EVs designed to transport large groups of people, or large amounts of cargo, or large loads, etc. The subject matter described with respect to Figures 28A-28C can be extended to even larger vehicles with two or more chassis and seven or more motors. The electrical connections between all the modules 108 can vary according to the embodiments described herein. The various assemblies 1250 can be configured similar to the embodiment of Figures 18A-18B and the parallel charging subject matter described herein. The modules 108 IC can interconnect all the subsystems 1000 by auxiliary load connections and can perform inter-array balancing between two or more arrays of the same or different subsystems. With reference to the electrical arrangement of Figures 18A-18B, the polyphase line 1111-3 and auxiliary load line 1802 can pass from area 180 to area 280 by electrical connection 2801. The arrangements 2800, 2820, and 2850 can be configured to charge according to any of the three-motor embodiments described herein and can include a charging connector and routing circuitry 1200.

Arrays 2800 and 2820 are similar except that area 280 is larger in array 2820 than in 2800, allowing room for additional modules, if desired. In these two embodiments, each subsystem 1000 includes three or more rows of modules 108, with all modules 108 oriented such that the longer dimension of each module is aligned along axis 2401 and the shorter dimension is aligned along axis 2402. Area 180 can be configured with an array similar to that of 2750 (as shown here), or with array 2700, or with others discussed herein. Subsystems 1000-5 and 1000-6 can be arranged in a front and back manner (FIG. 25A), or in a left and right manner as shown here, with each array aligned in rows along axis 2402 and each row aligned in columns along axis 2401.

The configuration of region 180 of array 2850 is similar to that of arrays 2800 and 2820. Region 280 of array 2850 is configured similarly to that of array 2550 (FIG. 25B), with the arrays in columns, each aligned along axis 2401, and the columns in rows, each aligned along axis 2402. Array 2850 has a second chassis that can house a subsystem that is even larger than those of 2800 and 2820 and capable of generating even more power.
Exemplary embodiments configured to power electric suspension and/or steering

Electric vehicles can be configured with electric (active) suspension mechanisms and/or electric steering (e.g., steer-by-wire) for each wheel. An electrically powered suspension works with electric actuators or motors to actively move the suspension in anticipation of vehicle or wheel movement (as opposed to a traditional passive suspension that only mechanically reacts to stimuli applied to the wheel or car). An electrically powered steering mechanism also works with electric actuators or motors to move the wheels in response to electrical signals passed by a steering controller (e.g., based on input by the driver to the steering wheel or by input from an automated driving control system).

The embodiments described herein can be utilized to power actuators or motors for electric suspension and/or steering. The embodiments can power electric suspension at any and all wheels, including but not limited to both electric suspension and electric steering at each wheel, and can power electric steering at both front wheels (and also rear wheels, if desired). The embodiments can power electric steering and suspension using a single three-phase system 100 with no subsystems, or with a system 100 having two, three, four, or more subsystems 1000.

FIG. 29A is a block diagram depicting an exemplary embodiment of system 100 having four subsystems 1000-1 to 1000-4, each configured to power a three-phase motor 1100 associated with the wheels of the EV and a DC actuator (or motor) 2900 associated with the wheels of the EV, which can be used for either electric suspension or electric steering. In FIG. 29A, each actuator 2900 is powered by an auxiliary load line 2902, which can be provided by one or more interconnection modules 108 IC. The voltage on line 2902 can be the same voltage as source 206 of interconnection module 108 IC, for example, obtained from ports 3 and 4, as described with respect to module 108C of FIG. 3C. Alternatively, the voltage on line 2902 can be down-regulated from the voltage of source 206 of module 108 IC, for example, obtained from ports 5 and 6. Alternatively, the connection to the lines 2902 can be omitted and each actuator 2900 can be powered directly from the module 108. The module 108 that provides the power can be a module located proximate to or relative to each actuator 2900.

29A depicts an alternative connection in which a line 2904 connects actuator 2900-1 to module 108-1 of array PA1 of subsystem 1000-1, which here is the corner module located closest to actuator 2900-1. If such a connection is used, actuator 2900-2 may be powered by module 108-1 of array PC2 of subsystem 1000-2, actuator 2900-3 may be powered by module 108-1 of array PA3 of subsystem 1000-3, and actuator 2900-4 may be powered by module 108-1 of array PC4 of subsystem 1000-4 by an additional line 2904 (not shown).

Actuator 2900 does not need to be powered directly by the corner module, but can be powered by any other module in the array closest to actuator 2900. Figure 29A depicts another alternative connection in which a line 2906 connects actuator 2900-3 to module 108-N of the PA3 array of subsystem 1000-3, which is located in the array closest to actuator 2900-3. Such a connection can be used as an alternative for each of the other actuators 2900 as well.

If each actuator 2900 is grounded, it may be desirable to provide isolation between the actuator 2900 and the system 100. FIG. 29A depicts another alternative connection in which an isolated converter 2910, which may be either a DC/DC converter or a DC/AC converter, is positioned on a line 2908 extending from module 108-1 of array PC4 of subsystem 1000-4 to actuator 2900-4. Such a connection 2908 can be used as an alternative for each of the other actuators 2900 as well. In other embodiments, an isolated converter 2910 can be interposed within line 2902 or 2906 to provide isolated power from those other sources. Although connections 2904, 2906, and 2908 are each shown as originating from a single module, such connections can originate from multiple modules 108 and utilize parallel energy sources.

An isolated converter can be integrated directly into module 108. Figure 29B is a block diagram depicting an example embodiment of module 108D configured with a DC/DC isolated converter 2910 to provide power from source 206 (or power wiring 110) to ports 7 and 8 connected to lines 2904 or 2906. Converter 2910 includes a DC/AC converter 2952 connected between I/O ports 7 and 8 and buffer 204 and connected to a transformer 2956 which in turn is connected to an AC/DC converter 2958. Converter 2958 can convert the DC voltage of source 206 to a high frequency AC voltage which transformer 2956 can modify to a different voltage if necessary and output the modified AC voltage to AC/DC converter 2952, which can convert the AC signal back to DC form for providing to actuator 2900. Transformer 2956 may also isolate module components 202, 204, 206, 2958, and 114 from ground. As with the other components of module 108D, monitor circuitry for converter 2952, transformer 2956, and converter 2958 may be included to measure current, voltage, temperature, faults, and the like. LCD 114 may monitor the status of converter 2910, and in particular converter 2952, transformer 2956 (e.g., monitor circuitry or active components associated therewith), and converter 2958, via data connections 118-5, 118-7, and 118-8, respectively. These connections 118-5 and 118-6 may also provide control signals to control the switching of converter 2952 and any controllable elements therein associated with transformer 2956. Isolation of LCD 114 can be maintained by isolation circuitry (eg, isolated gate drivers and isolated sensors) present on lines 118-5 and 118-6.

29C is a schematic diagram depicting an exemplary embodiment of module 108D. Converter 202A is coupled to buffer 204, which is configured as a capacitor. I/O ports 7 and 8 are coupled to optional LC filter 2902, which in turn is coupled to converter 2910, specifically DC/AC converter 2952, which is configured as a full bridge converter with switches S10, S11, S12, and S13. The full bridge output from nodes N1 and N2 is connected to a primary winding of transformer 2956. The secondary winding of transformer 2956 is coupled to nodes N3 and N4 of a second full bridge circuit, configured as AC/DC converter 2958, having switches S14, S15, S16, and S17. The switches of converter 2958 can be semiconductor switches, configured as MOSFETs, IGBTs, GaN devices, or others as described herein. The LCD 114 or another element of the control system 102 may provide the switching signals for control of the switches S1-S6 and S10-S17.

29D is a schematic diagram depicting another exemplary embodiment of module 108D in which AC/DC converter 2958 is configured as a push-pull converter with switches S18 and S19 connected between a first terminal of source 206 connected to one side of a dual secondary winding of transformer 2956 through inductor L2 and a common node (e.g., node 4) that is coupled to the opposite side of the dual secondary winding and the opposite terminal of source 206. The push-pull configuration requires only two switches and is therefore more cost effective than a full bridge converter, but the switches have a larger voltage applied across them.

Various aspects of the present subject matter are described below as elaboration and/or complementation of previously described embodiments, with emphasis placed on the interrelationship and interchangeability of the following embodiments, in other words, on the fact that each feature of the embodiments can be combined with each and every other feature, unless expressly stated or taught otherwise.

In many embodiments, a modular energy system is provided that is controllable to supply power to a load, the modular energy system including three arrays, each including at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter, a charging port configured to conduct a DC or single-phase AC charging signal, and routing circuitry connected between the charging port and the three arrays, the routing circuitry being controllable to selectively route the DC or single-phase AC charging signal to each of the three arrays.

In some embodiments, the system further includes a control system communicatively coupled to the routing circuitry, the control system configured to control the routing circuitry to selectively route the DC or single-phase AC charging signals to each of the three arrays.

In some embodiments, the control system is communicatively coupled to each module of the three arrays and configured to control the converters of each module and charge each module.

In some embodiments, the control system is configured to control the converter of each module according to a pulse width modulation or hysteresis technique. Each module can include monitor circuitry configured to monitor status information of the module, each module configured to output the status information to the control system, and the control system configured to control the converter of each module based on the status information. The status information can relate to the temperature and charge state of the module, and the control system is configured to control the converter of each module to balance the temperature and charge state of all modules in the array.

In some embodiments, the routing circuitry includes a plurality of unidirectional solid-state repeaters controllable by the control system to selectively route the DC charging signal to each of the three arrays. The unidirectional solid-state repeaters can be thyristors.

In some embodiments, the routing circuitry includes a first port coupled to the DC+ line, a second port coupled to the DC- line, a third port coupled to the first array, a fourth port coupled to the second array, and a fifth port coupled to the third array, and includes a first thyristor coupled between the first port and the third port, a second thyristor coupled between the first port and the fourth port, a third thyristor coupled between the fourth port and the second port, and a fourth thyristor coupled between the fifth port and the second port, the thyristors being controllable by a control system to selectively route a DC charging signal at the first port to either the third or fourth port and selectively route a signal at the fourth or fifth port to the second port. The routing circuitry may include a sixth port coupled to the first AC line and a seventh port coupled to the second AC line, and may include a first diode coupled between the seventh port and the first and second thyristors, a second diode coupled between the sixth port and the first and second thyristors, a third diode coupled from the third and fourth thyristors to the sixth port, and a fourth diode coupled from the third and fourth thyristors to the seventh port.

In some embodiments, the routing circuitry includes a plurality of bidirectional solid-state repeaters controllable by the control system to selectively route DC or single-phase AC charging signals to each of the three arrays. The bidirectional solid-state repeaters can be triacs.

In some embodiments, the routing circuitry includes a first port configured to couple to a DC+ charging signal or a single phase AC line charging signal, a second port configured to couple to a DC- charging signal or a single phase AC neutral signal, a third port coupled to the first array, a fourth port coupled to the second array, and a fifth port coupled to the third array, and includes a first triac coupled between the first port and the third port, a second triac coupled between the first port and the fourth port, a third triac coupled between the fourth port and the second port, and a fourth triac coupled between the fifth port and the second port. The triac can be controllable by the control system to selectively route a DC charging signal at the first port to either the third or fourth port and to selectively route the signal at the fourth or fifth port to the second port when operating in a DC charging state, and the triac can be controllable by the control system to selectively route an AC line charging signal at the first port to either the third or fourth port and to selectively route the signal at the fourth or fifth port to the second port when operating in a positive single-phase AC charging state, and to selectively route the signal at the second port to either the fourth or fifth port and to selectively route the signal at the third or fourth port to the first port when operating in a negative single-phase AC charging state.

In some embodiments, the charging port is configured to conduct a three-phase AC charging signal, and the routing circuitry includes a plurality of bidirectional solid-state repeaters controllable by the control system to selectively route DC or single-phase AC charging signals to each of the three arrays. The plurality of bidirectional solid-state repeaters can include triacs. The routing circuitry may include a first port configured to receive a DC or AC charging signal, a second port configured to receive an AC charging signal, and a third port configured to receive a DC or AC charging signal, and may further include a first triac coupled between the first port and a first line connectable to a first array of the three arrays, a second triac coupled between the second port and a second line connectable to a second array of the three arrays, a third triac coupled between the third port and a third line connectable to a third array of the three arrays, a fourth triac coupled between the first line and the second line, and a fifth triac coupled between the second line and the third line.

In some embodiments, the system is further configured to selectively disconnect all of the modules and the motor from the charging source.

In some embodiments, the three arrays can be interconnected by at least one interconnect module. The control system can be configured to control the at least one interconnect module to supply voltage for the at least one auxiliary load when the system is in a charging state.

In some embodiments, the three arrays are interconnected in a delta series configuration.

In some embodiments, the load is a six-phase load, the three arrays are a first set of arrays, and the system further includes a second set of arrays including an additional three arrays of modules, and the system is configured to charge the first and second sets of arrays in parallel.

In some embodiments, the charging port is a first charging port and the system further includes a second charging port configured to receive a three-phase charging signal, the first and second charging ports are integrated within the same user-accessible location, and the routing circuitry can be connected to lines from the second charging port.

In some embodiments, the system includes a plurality of switches coupled between the first module of each array and a load, the plurality of switches being controllable to disconnect the load from the three arrays.

In some embodiments, the three arrays are of a first subsystem of a system configured to provide three-phase power to a first load, the system further including a second subsystem configured to provide three-phase power to a second load, the second subsystem including three arrays each including at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module of the second subsystem including an energy source and a converter, the first and second subsystems coupled together by a first plurality of switches such that the first and second subsystems are electrically connectable in parallel for charging. The system may further include a third subsystem configured to provide three-phase power to a third load, the third subsystem including three arrays including at least two modules each electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each of the modules of the third subsystem including an energy source and a converter, and the first and third subsystems coupled together by a second plurality of switches such that the first and third subsystems are electrically connectable in parallel for charging.

In many embodiments, a method of charging a modular energy system is provided, the modular energy system configured according to any of the embodiments disclosed herein, the method including controlling the modular energy system while a charging signal is applied to charge the modular energy system and balance at least one operating characteristic of the system. The at least one operating characteristic can be temperature. The charging signal can be a three-phase charging signal, a single-phase charging signal, or a direct current (DC) charging signal. The modular energy system can be controlled to maintain a power factor of the system within a threshold of unity. Controlling the modular energy system can include controlling converters of modules of the energy system.

In many embodiments, a computer-readable medium is provided that includes a plurality of instructions that, when executed by processing circuitry, cause the processing circuitry to control charging for a modular energy system, the modular energy system being configured according to any of the embodiments disclosed herein.

In many embodiments, a modular energy system for an electric vehicle (EV) is provided, the system including a first subsystem configured to supply power to a first motor of the EV, the first subsystem including three arrays including at least two first modules each electrically connected together and outputting an AC voltage signal including a superposition of an output voltage from each of the at least two first modules, each first module including an energy source and a converter; a second subsystem configured to supply power to a second motor of the EV, the first subsystem including three arrays including at least two second modules each electrically connected together and outputting an AC voltage signal including a superposition of an output voltage from each of the at least two second modules, each second module including an energy source and a converter; and a plurality of switches configured to selectively connect the first and second subsystems to charge, wherein a nominal output voltage of the first subsystem exceeds a nominal output voltage of the second subsystem.

In some embodiments, each array of the first subsystem includes more modules than each array of the second subsystem.

In some embodiments, the nominal voltage of each first module exceeds the nominal voltage of each second module.

In some embodiments, the energy source of each first module is a first type of battery and the energy source of each second module is a second type of battery, the first type being different from the second type, the first type may have a relatively greater energy density than the second type, and the second type may have a relatively greater C-rate than the first type.

In some embodiments, the plurality of switches can be configured to connect the first array of the first subsystem to the first array of the second subsystem in parallel, the second array of the first subsystem to the second array of the second subsystem in parallel, and the third array of the first subsystem to the third array of the second subsystem in parallel. The system can further include a charge port configured to conduct a DC or single-phase AC charging signal, and a routing circuitry connected between the charge port and the subsystems, the routing circuitry being controllable to selectively route the DC or single-phase AC charging signal to each parallel connection of the subsystem arrays. The system can further include a control system communicatively coupled to the routing circuitry and the plurality of switches, the control system configured to control the selective routing of the routing circuitry. The control system can be communicatively coupled to the converters of each first module and each second module and configured to control the converters to charge each first and second module.

In some embodiments, the system further includes a third subsystem configured to supply power to a third motor of the EV, the third subsystem including three arrays including at least two third modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two third modules, each third module including an energy source and a converter. The plurality of switches can be a first plurality of switches, and the system further includes a second plurality of switches configured to selectively connect the second and third subsystems for charging. The maximum output voltage of the first subsystem can be greater than the maximum output voltage of the third subsystem. The first motor can be configured to power rear wheels of the EV, the second motor can be configured to power a first front wheel of the EV, and the third motor can be configured to power a second front wheel of the EV. The system may further include a fourth subsystem configured to supply power to a fourth motor of the EV, the fourth subsystem including three arrays including at least two fourth modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two fourth modules, each of the fourth modules including an energy source and a converter.

In some embodiments, the nominal output voltage of the first subsystem is the nominal peak line-to-line output voltage of the first subsystem and the nominal output voltage of the second subsystem is the nominal peak line-to-line output voltage of the second subsystem.

In many embodiments, a modular energy system is provided that is controllable to supply power to a closed winding motor, the system including three arrays, each array including at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter, and a charging connector including a first port and a second port and configured to conduct a DC or single phase AC charging signal, a first charging path extends from the first port, through the first and second windings of the motor, through the first array and terminating at the second port, a second charging path extends from the first port, through the first and third windings of the motor, through the second array and terminating at the second port, and a third charging path extends from the first port of the connector, bypasses the motor, passes through the third array and terminates at the second port.

In some embodiments, the system further includes a control system communicatively coupled to the modules of the three arrays, the control system configured to control the converters of each module to charge each module. The control system can be configured to charge each of the three arrays in parallel with a DC charging signal. The control system can be configured to charge two of the three arrays in parallel with a DC charging signal. The control system can be configured to charge each of the three arrays in sequence with a DC charging signal. The control system can be configured to charge each of the three arrays in parallel with a single-phase AC charging signal. The control system can be configured to charge two of the three arrays in parallel with a single-phase AC charging signal. The control system can be configured to charge each of the three arrays in sequence with a single-phase AC charging signal. The control system can be configured to charge in parallel along the first and second charging paths such that flux generated on the first, second, and third windings of the motor is neutralized.

In some embodiments, the system further includes a three-phase charging connector connected to the plurality of switches, the switches being controllable by the control system to selectively connect the three-phase charging connector to the three arrays.

In some embodiments, the control system can be configured to control the converter of each module according to a pulse width modulation or hysteresis technique. Each module can include monitor circuitry configured to monitor status information of the module, each module configured to output the status information to the control system, and the control system configured to control the converter of each module based on the status information. The status information can relate to the temperature and charge state of the module, and the control system is configured to control the converter of each module to balance the temperature and charge state of all modules in the array.

In some embodiments, the three arrays are interconnected by at least one interconnect module. The control system can be configured to control the at least one interconnect module to supply voltage for the at least one auxiliary load when the system is in a charging state.

In many embodiments, a charging source configured to charge an electric vehicle (EV) is provided, the charging source including a modular energy system including three arrays configured to generate power in at least three phases, each array including at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter.

In some embodiments, the charging source is configured to connect to an external power supply and charge the energy source of the modular energy system. The external power supply can be a grid or a renewable energy source. The charging source can be configured to charge the EV at a first rate, and the charging source is configured to be charged by the external power supply at a second rate, the first rate being greater than the second rate.

In some embodiments, the charging source includes monitor circuitry configured to detect harmonics, which can be output to an external power supply, and a control system configured to control a converter of the module to generate a compensation current to cancel the harmonics. The charging source can further include a DC/AC converter including a plurality of diodes for rectification.

In some embodiments, the charging source can be configured to charge the EV with a DC charging signal, a single-phase AC charging signal, or a three-phase AC charging signal.

In some embodiments, an EV can include a battery pack including a modular energy system including three arrays configured to generate power in at least three phases, each array including at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter.

In many embodiments, a modular energy system is provided that is controllable to supply power to an open winding motor, the system including a first subsystem including three arrays, each array including at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter, the first subsystem being connected to a three-phase charging connector; and a second subsystem including three arrays, each array including at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter, the first subsystem being connected to a three-phase charging connector. and a second subsystem including an energy source and a converter, the first and second subsystems being configured to connect to the motor such that a first winding of the motor is connected between a first array of the first subsystem and a first array of the second subsystem, a second winding of the motor is connected between a second array of the first subsystem and a second array of the second subsystem, and a third winding of the motor is connected between a third array of the first subsystem and a third array of the second subsystem.

In some embodiments, a first port of the three phase charging connector is coupled to a first array of the first subsystem, a second port of the three phase charging connector is coupled to a second array of the first subsystem, and a third port of the three phase charging connector is coupled to a third array of the first subsystem, the system further including a first switch coupled between the first port and the second port, a second switch coupled between the second port and the third port, and a DC or single phase AC charging connector coupled to the third port and the third array of the second subsystem.

In many embodiments, a modular energy system for an electric vehicle (EV) is provided, the system including three arrays, each including at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, the modules each including an energy source and a converter, the three arrays configured to provide three-phase power for a first electric motor configured to provide motive power for at least one wheel of the EV, and at least one module of the three arrays configured to provide power to a second electric motor of an electric suspension or electric steering mechanism of the EV.

In some embodiments, the system can be configured to provide power for two second electric motors of the EV.

In some embodiments, the system can be configured to provide power for four second electric motors of an EV.

In some embodiments, the at least one module is the module of the array of three closest to the second electric motor.

In some embodiments, at least one module is configured as an interconnect module that is coupled to at least two of the three arrays.

In some embodiments, the system includes a plurality of interconnection modules coupled between the three arrays, each interconnection module including an energy source and a converter, the energy sources of the interconnection modules being connected in parallel. At least one module can be one of the plurality of interconnection modules.

In some embodiments, the system further includes an isolated converter, and at least one module of the three arrays is configured to provide power to the second electric motor using the isolated converter.

In some embodiments, the converter of the at least one module includes a first converter, the at least one module includes an isolated converter coupled to an energy source of the at least one module, the at least one module configured to provide power from the energy source through the isolated converter to the second electric motor. The isolated converter can include a first DC/AC converter coupled to the energy source of the at least one module, a transformer coupled to the DC/AC converter, and a second DC/AC converter coupled to the transformer.

In some embodiments, the second electric motor is an electric actuator.

In some embodiments, the second electric motor is part of the electric suspension of the EV.

In some embodiments, the second electric motor is part of an electric steering mechanism of the EV.

In some embodiments, the three arrays are of a first subsystem of a system, the system further including at least one additional subsystem configured to provide three-phase power for a third electric motor of the EV, the at least one additional subsystem configured to provide motive power for at least one wheel of the EV, the at least one additional subsystem including at least one additional module configured to provide power to a fourth electric motor of an electric suspension or electric steering mechanism of the EV.

In many embodiments, a modular energy system for an electric vehicle (EV) is provided, the system including three arrays, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter, a chassis of the EV having a first axis and a second axis perpendicular to a horizontal plane of the EV, a first dimension of the chassis along the first axis being relatively longer than a second dimension of the chassis along the second axis, the three arrays arranged in a pack configured to fit within the chassis, each module of the three arrays having a first dimension aligned along the first axis and a second dimension aligned along the second axis, the second dimension of each module being relatively larger than the first dimension.

In some embodiments, for each array, a majority of the modules of the array are aligned along a first axis.

In some embodiments, a first stage of the array is arranged in an alternating manner at a first end of the pack, and another stage of the array is aligned along a second axis. The system can further include a plurality of interconnection modules arranged in an alternating manner at a second end of the pack.

In some embodiments, the system can be configured to provide three-phase power to a motor located adjacent a first end of the pack.

In some embodiments, the three arrays are of a first subsystem, and the system further includes a second subsystem including three arrays of modules arranged in a symmetrical opposed manner relative to the first subsystem, and the system can further include a plurality of interconnected modules positioned between the first and second subsystems and aligned along a second axis.

In many embodiments, a modular energy system for an electric vehicle (EV) is provided, the system comprising: a first subsystem including three arrays configured to provide three-phase power to a first motor of the EV, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter; and a second subsystem including three arrays configured to provide three-phase power to a second motor of the EV, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules. The EV includes at least two stages of modules that output an AC voltage signal including a superposition of output voltages therefrom, each of the modules including a second subsystem including an energy source and a converter, the EV's chassis having a first axis and a second axis perpendicular to a horizontal plane of the EV, a first dimension of the chassis along the first axis being relatively longer than a second dimension of the chassis along the second axis, the two subsystems arranged in a pack configured to fit within the chassis, each module of the two subsystems having a first dimension aligned along the first axis and a second dimension aligned along the second axis, the second dimension of each module being relatively smaller than the first dimension.

In some embodiments, for each array, a majority of the modules in the array are aligned along a first axis. Each row of the array can be aligned along a second axis. The system can further include a plurality of interconnection modules arranged in an alternating manner at the first end of the pack.

In some embodiments, the first and second subsystems are configured to output power for the first and second motors at the second end of the pack.

In many embodiments, a modular energy system for an electric vehicle (EV) is provided, the system comprising: a first subsystem including three arrays configured to provide three-phase power to a first motor of the EV, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter; a second subsystem including three arrays configured to provide three-phase power to a second motor of the EV, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter; a third subsystem including three arrays configured to provide power to a third motor of the EV, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each of the modules including an energy source and a converter; a chassis of the EV having a first axis and a second axis perpendicular to a horizontal plane of the EV, a first dimension of the chassis along the first axis being relatively longer than a second dimension of the chassis along the second axis, the three subsystems arranged in a pack configured to fit within the chassis, each module of the first and second subsystems having a first dimension aligned along the first axis and a second dimension aligned along the second axis, the second dimension of each module being relatively smaller than the first dimension.

In some embodiments, each module of the third subsystem has a first dimension aligned along a first axis and a second dimension aligned along a second axis, the second dimension of each module being relatively larger than the first dimension.

In some embodiments, the first subsystem is positioned on the left side of the EV and the second subsystem is positioned on the right side of the EV. The third subsystem is behind the first and second subsystems. The first subsystem is configured to power a first motor for the front left wheels of the EV, the second subsystem is configured to power a second motor for the front right wheels of the EV, and the third subsystem is configured to power a third motor for the rear wheels of the EV.

In some embodiments, the system further includes a plurality of interconnection modules positioned between the first subsystem and the second subsystem.

In some embodiments, each array of the first and second subsystems is aligned along a second axis.

In some embodiments, the stages of each module of the first and second subsystems are aligned along the first axis.

In some embodiments, a majority of the modules in each array of the third subsystem are aligned along the first axis.

In some embodiments, a majority of the stages of the modules of the third subsystem are aligned along the second axis. A first stage of the modules of the third subsystem are arranged in an alternating manner.

In many embodiments, a modular energy system for an electric vehicle (EV) is provided, the system including four subsystems configured to provide three-phase power to four motors of the EV, each subsystem including three arrays, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter, a chassis of the EV having a first axis and a second axis perpendicular to a horizontal plane of the EV, a first dimension of the chassis along the first axis being relatively longer than a second dimension of the chassis along the second axis, the four subsystems arranged in a pack configured to fit within the chassis, each module of the first and second subsystems having a first dimension aligned along the first axis and a second dimension aligned along the second axis, the second dimension of each module being relatively smaller than the first dimension.

In some embodiments, the system further includes a plurality of interconnection modules aligned along the first axis.

In some embodiments, the four subsystems are a first subsystem, a second subsystem, a third subsystem, and a fourth subsystem, and the four motors are a first motor, a second motor, a third motor, and a fourth motor, and the system further includes a fifth subsystem configured to provide three-phase power to a fifth motor of the EV, the fifth subsystem including three arrays, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter, and a sixth subsystem configured to provide three-phase power to a sixth motor of the EV, the sixth subsystem including three arrays, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter.

In some embodiments, the chassis is a first chassis, the pack is a first pack, and the fifth and sixth subsystems are arranged within a second pack configured to fit within a second chassis of the EV that is movably coupled to the first chassis.

In many embodiments, a modular energy system for an electric vehicle (EV) is provided, the system including four subsystems configured to provide three-phase power to four motors of the EV, each subsystem including three arrays, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter, a chassis of the EV having a first axis and a second axis perpendicular to a horizontal plane of the EV, a first dimension of the chassis along the first axis being relatively longer than a second dimension of the chassis along the second axis, the four subsystems arranged in a pack configured to fit within the chassis, each module of the first and second subsystems having a first dimension aligned along the first axis and a second dimension aligned along the second axis, the second dimension of each module being relatively larger than the first dimension.

In some embodiments, the system further includes a plurality of interconnection modules aligned along a second axis.

In some embodiments, the four subsystems are a first subsystem, a second subsystem, a third subsystem, and a fourth subsystem, and the four motors are a first motor, a second motor, a third motor, and a fourth motor, and the system further includes a fifth subsystem configured to provide three-phase power to a fifth motor of the EV, the fifth subsystem including three arrays, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter, and a sixth subsystem configured to provide three-phase power to a sixth motor of the EV, the sixth subsystem including three arrays, each array including a stage of at least two modules electrically connected together and outputting an AC voltage signal including a superposition of output voltages from each of the at least two modules, each module including an energy source and a converter. The chassis can be a first chassis and the pack can be the first pack, and the fifth and sixth subsystems can be arranged within a second pack configured to fit within a second chassis of the EV that is movably coupled to the first chassis.

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

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

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

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

The term "nominal voltage" is a metric commonly used to describe battery cells and is provided by the manufacturer (e.g., by marking on the cell or in a data sheet). Nominal voltage often refers to the average voltage that the battery cell outputs when charged, and can be used to describe the voltage of entities that incorporate the battery cells, such as the subject battery modules and subsystems and systems.

The term "C-rate" is a metric commonly used to describe the discharge current divided by the theoretical draw current below which a battery would deliver its nominal rated capacity within one hour.

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

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

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

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

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

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

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

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

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

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

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

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

Claims (25)

1. A modular energy system controllable to supply power to a load, the system including:
There are three arrays, each array including at least two modules electrically connected to output an alternating voltage signal consisting of a superposition of output voltages from at least two modules, each of the modules including an energy source and a converter;
a charging port configured to conduct a DC or single phase AC charging signal; and a routing circuit connected between the charging port and the three arrays, the routing circuit being controllable to selectively route the DC or single phase AC charging signal to each of the three arrays. The system of claim 1, further comprising a control system communicatively coupled to the routing circuitry, the control system configured to control the routing circuitry to selectively route the DC or single-phase AC charge signal to each of the three arrays. The system of claim 2, wherein the control system is communicatively coupled to each module of the three arrays and configured to control a converter in each module to charge each module. The system of claim 3, wherein the control system is configured to control the converters of each module according to a pulse width modulation or hysteresis technique. The system of claim 3, wherein each module includes a monitor circuit configured to monitor status information of the module, each module is configured to output the status information to a control system, and the control system is configured to control a converter of each module based on the status information. The system of claim 5, wherein the status information relates to temperature and charge state of the modules, and the control system is configured to control the converters of each module to balance the temperature and charge state of all modules in the array. The system of claim 2, wherein the routing circuitry includes a plurality of one-way solid-state relays controllable by the control system to selectively route the DC charge signal to each of the three arrays. The system of claim 2, wherein the routing circuitry includes a plurality of bidirectional solid-state relays controllable by the control system to selectively route DC or single-phase AC charge signals to each of the three arrays. In the system of claim 2, the charging port is configured to conduct a three-phase AC charging signal, and the routing circuitry comprises a plurality of bidirectional solid-state relays controllable by the control system to selectively route DC or single-phase AC charging signals to each of the three arrays. The system of claim 1 , further configured to selectively disconnect all of the modules and the motor from the charging source. A system according to any preceding claim, wherein the three arrays are interconnected in a delta series configuration. 12. The system of claim 1, wherein the load is a six-phase load, the three arrays are a first set of arrays, and the system further includes a second set of arrays including an additional three arrays of modules, and the system is configured to charge the first and second sets of arrays in parallel. A system according to any preceding claim, wherein the charging port is a first charging port, and the system further comprises a second charging port configured to receive a three-phase charging signal. 14. The system of claim 13 , wherein the first and second charging ports are integrated in a same user accessible location. 14. The system of claim 13 , wherein the routing circuit is connected to a line from the second charging port. 16. The system of claim 1, further comprising a plurality of switches coupled between the first module of each array and a load, the plurality of switches being controllable to disconnect the load from the three arrays. 17. The system of claim 1, wherein the three arrays are of a first subsystem of the system configured to supply three-phase power to a first load, the system further comprising a second subsystem configured to supply three-phase power to a second load, the second subsystem being three arrays each including at least two modules electrically connected together to output an AC voltage signal consisting of a superposition of output voltages from each of the at least two modules, the modules of the second subsystem consisting of an energy source and a converter;
The first and second subsystems are characterized in that they are coupled together by a first plurality of switches such that the first and second subsystems are electrically connectable in parallel for charging. 18. The system of claim 17, further comprising a third subsystem configured to supply three-phase power to a third load, the third subsystem comprising three arrays each including at least two modules electrically connected together to output an AC voltage signal comprising a superposition of output voltages from each of the at least two modules, each of the modules of the third subsystem including an energy source and a converter .
The first and third subsystems are coupled together by a second plurality of switches such that the first and third subsystems are electrically connectable in parallel for charging. A method of charging a modular energy system constructed according to any one of claims 1 to 18 , comprising:
Controlling the modular energy system while a charging signal is applied to charge the modular energy system and balance at least one operating characteristic of the system. The method of claim 19 , wherein the at least one operating characteristic is temperature. 20. The method of claim 19 , wherein the charge signal is a three-phase charge signal, a single-phase charge signal, or a direct current (DC) charge signal. 20. The method of claim 19 , wherein the modular energy system is controlled to maintain a power factor of the system within a threshold of unity. 20. The method of claim 19 , wherein controlling the modular energy system includes controlling converters of modules of the energy system. A control system for a modular energy system constructed according to any one of claims 1 to 18 . A computer readable medium comprising a plurality of instructions that, when executed by a processing circuit, cause the processing circuit to control charging of a modular energy system configured according to any of claims 1 to 18 .