Abstract:
A modular power backup system has a plurality of smart battery packs for storing electrical energy. Each of the plurality of smart battery packs includes a first power and control connector. A battery pack rack defines a plurality of slots for holding the plurality of smart battery packs. Each of the plurality of slots includes a second power and control connector for interconnecting with the first power and control connector of a smart battery pack of the plurality of smart battery packs. First control circuitry associated with the at least one battery pack rack selectively pools electrical energy from the plurality of smart battery packs into one or more electrical energy outputs.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims benefit of U.S. Provisional Application No. 61/856,698, filed Jul. 20, 2013, entitled MODULAR CUSTOMER PREMISES GRID POWER BACKUP SYSTEM (Atty. Dkt. No. ASPS-31818), the specification of which is incorporated by reference herein in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to backup power systems, and more particularly, to a modular backup power system including a plurality of smart battery packs in one or more racks. 
       BACKGROUND 
       [0003]    Current customer premises power backup systems typically include a diesel engine electrical generator that provides direct AC power to the customer&#39;s premises, or alternatively, a bank of photovoltaic solar panels that are used to charge a bank of lead acid batteries that subsequently provide AC electricity through invertors that are connected to a premises distribution panel or junction box. Irrespective of the source of energy that is used to provide backup electrical power, whether from photovoltaic panels or from the utility grid, neither of these methods provides a particularly flexible use or implementation. Additionally, these solutions require a substantial financial expenditure up front in order to provide either a diesel backup engine or to provide the photovoltaic panels for generating the electricity in the bank of lead acid batteries for storing the energy. Thus, there is a need for a more cost effective and easier solution for providing backup power to a customer premises than those described herein above. 
       SUMMARY 
       [0004]    The present invention, as disclosed and described herein, in one aspect thereof, comprises a modular power backup system having a plurality of smart battery packs for storing electrical energy. Each of the plurality of smart battery packs includes a first power and control connector. A battery pack rack defines a plurality of slots for holding the plurality of smart battery packs. Each of the plurality of slots includes a second power and control connector for interconnecting with the first power and control connector of a smart battery pack of the plurality of smart battery packs. First control circuitry associated with the at least one battery pack rack selectively pools electrical energy from the plurality of smart battery packs into one or more electrical energy outputs. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    For a more complete understanding, reference is now made to the following description taken in conjunction with the accompanying Drawings in which: 
           [0006]      FIG. 1  is a block diagram illustrating the manner in which a plurality of smart battery packs are utilized for providing backup energy power via a rack-based system; 
           [0007]      FIG. 2  provides a front view of a smart battery pack; 
           [0008]      FIG. 3  provides a back view of the smart battery pack; 
           [0009]      FIG. 4A  illustrates a block diagram of a smart battery pack; 
           [0010]      FIG. 4B  illustrates a block diagram of system elements consisting of the smart battery pack that connects to various functional modular units to provide a basic portable solar generator solution; 
           [0011]      FIG. 5  illustrates a front view of a rack for containing smart battery packs; 
           [0012]      FIG. 6  provides a back view of the rack for containing smart battery packs; 
           [0013]      FIG. 7  illustrates a block diagram of the control components of the rack; 
           [0014]      FIG. 8  illustrates the manner in which a plurality of racks may be integrated and controlled; 
           [0015]      FIG. 9  illustrates a block diagram of the system elements of the backup power system between various charging sources and a customer utility interface; and 
           [0016]      FIG. 10  illustrates an example of a design implementation for modular grid power backup system. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Referring now to the drawings, wherein like reference numbers are used herein to designate like elements throughout, the various views and embodiments of modular grid power backup system are illustrated and described, and other possible embodiments are described. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated and/or simplified in places for illustrative purposes only. One of ordinary skill in the art will appreciate the many possible applications and variations based on the following examples of possible embodiments. 
         [0018]    Referring now to the drawings, and more particularly to  FIG. 1 , there is illustrated a functional block diagram of a power storage backup system  100 . The power storage backup system  100  includes one or more removable smart battery packs  102  that are electrically interconnected with each other upon insertion of the battery packs  102  into one or more racks  104  for charging or power supplying. A battery power distribution mechanism  106  associated with the rack  104  manages the utilization of the smart battery packs  102  as an energy source for providing power to various electric loads. The racks  104  additionally provide load circuit management  108  for managing the electricity supply to various load circuit at the customer premises that are interconnected with the energy providing racks. 
         [0019]    The implementation of the power storage backup system  100  of  FIG. 1  depends upon a user&#39;s particular circumstances and financial ability. A user may initially begin with a single portable smart battery pack  102  as illustrated in  FIGS. 2 and 3 .  FIG. 2  illustrates a front side panel of the smart battery pack  102  while  FIG. 3  illustrates the back power interconnection side of the smart battery pack  102 . Using a smart battery pack  102 , a user may charge the battery pack  102  using a DC charger plugged into the power grid such that the battery pack is available as a portable backup power pack when needed. The front panel of the battery pack  102  includes a universal AC outlet  202  for providing an interconnection to the internal battery via the standard AC power plug connect. The AC on/off switch  204  comprises a push button or two-position switch which may be used for turning on and off power to the universal AC outlet  202 . A 120/240-volt selector switch  206  enables a selection of either 120-volt power or 240-volt power at the AC outlet  202  providing power from the smart battery pack  102 . A 12-volt DC output connector  208  allows the provision of 12-volt DC power through a DC power cord. 
         [0020]    The output interface of the front panel additionally provides for USB outlets  210 . The USB outlets  210  enable the connection of a USB connector to charge a device through the USB outlet  210 . The front interface of the smart battery pack  102  additionally includes a 15-volt DC connector  212 . This enables 15-volt DC power to be provided to the battery pack  102 . The DC input voltage of 15-volts is just one of the possible implementations. All input and output voltages may be set to various values as necessitated by the intended application. A system status display  214  provides a window for displaying various types of system status information such as whether the battery pack is turned on and providing power and what type of power output or outputs are being provided from the battery pack  102 . The main power switch  216  provides the manner for turning on and off the smart battery pack  102 . The main power switch  216  enables the user to selectively provide power from the battery pack  102  as desired. 
         [0021]    Referring now to  FIG. 3 , the back panel of the smart battery pack  102  is illustrated. The back panel provides a power and control connector  302 . The power and control connector  302  enables the provision of stored battery power from the battery pack  102  when the battery pack  102  is included within a system rack as will be described more fully herein below. Additionally, the power and control connector  302  enables control of the battery pack  102  such that the energy stored by the battery pack  102  may be combined with the energy of other battery packs  102  when the battery pack is located within a system rack in order to provide a higher level of power to run larger load electrical devices. 
         [0022]    Referring now to  FIG. 4A , there is provided a block diagram of a smart battery pack  102  according to one embodiment. The battery pack  102  may be charged in one of two manners. The battery pack  102  may be charged via a DC input socket which in  FIG. 4A  comprises a 15-volt input socket  212 . The 15-volt DC input socket  212  interconnects with a 15-volt DC battery charger  402  that provides a charging voltage to the battery pack  102 . The DC charger  402  would be powered either from a standard alternating current source or through a standard 12-volt cigarette lighter socket. Additionally, the battery pack  102  may be charged from its rear panel power and control connector  302 . The power and control connector  302  mates with a power control termination point  404  on the rear of a battery pack rack  502  (see  FIG. 6 ). The rack  502  is equipped with power control termination points that the battery pack  102  can mate with when the battery packs  102  are inserted within the rack  502 . 
         [0023]    When the battery pack  102  is inserted into a rack  502  for charging through the power control termination point  404 , the 15-volt DC input socket  212  is disabled by the charging control and detection circuitry  406  responsive to commands from the microcontroller unit  408 . In this situation, the charging control and detection circuitry  406  would receive an indication from the power and control connector  302  that the power control termination point  404  had been connected therewith. These indications would be forwarded to the microcontroller unit  408 . The microcontroller unit  408  would instruct the control and connection circuitry  406  to disable the 15-volt DC input socket  212  while receiving the charging voltage from the power and control connector  302 . The power and control connector  302 , in addition to providing for the charging of the internal battery  410  of the battery pack  102 , provides access to control and monitor the operation of the battery pack  102  from external control circuitries. 
         [0024]    The battery pack  102  includes a microcontroller unit  408  which is responsible for controlling all monitoring and control operations within the smart battery pack  102 . The microcontroller unit  408  provides a display signal to the LCD display  214  that provides status information with respect to the operation of the smart battery pack  102  in a visual manner through the front display  214 . As discussed previously, the microcontroller unit  408  additionally communicates with the charging control and detection circuitry  406 . The charging control and detection circuitry  406  detects a connection of either the 15-volt charging source  402  or power control termination point  404  at the associated 15-volt DC input socket connectors  212  and power and control connector  302 . As discussed previously, when a power control termination point  404  is interconnected with the power and control connector  302 , the 15-volt DC input socket  212  is disabled. Similarly, when the power and control connector  302  of the battery pack  102  is not connected to the power control termination point  404  and a charger is interconnected with the 15-volt DC input socket  212 , the power and control connector  302  is disabled such that charging voltage comes solely through the 15-volt DC input socket  212 . 
         [0025]    The charging control and detection circuitry  406  is also interconnected with the power management and monitoring circuit  412  that provides connection of the charging voltages to the battery  410 . In the charging mode, the power management and monitoring circuit  412  monitors the charge level of the battery  410  and continues providing a charging voltage from either the 15-volt DC input socket  212  or the power and control connector  302  until the power management and monitoring circuit  412  determines that the battery  410  is fully charged. Once the battery  410  is fully charged, the charging voltage would be disconnected from the battery  410  in order to prevent overcharging issues within the battery  410 . The power management and monitoring circuits  412  additionally monitor for connections to each of the AC output  202 , USB outputs  210  and 12-volt DC output  208  to determine if connections are provided to any of these outputs requiring the provision of output voltage thereto from the battery  410 . 
         [0026]    The power management and monitoring circuits  412  would include one or more DC to DC convertors for providing a DC voltage to the USB outputs  210  and to the 12-volt DC output  208  from the battery  410  when a DC power requiring load was connected. Additionally, the power management and monitoring circuit  412  would include one or more DC to AC invertors for providing an output AC voltage to the AC output  202  for AC connected loads. The battery  410  in one embodiment would comprise a lithium iron phosphate (also known as LFP) battery. It will be understood, of course, that other types of rechargeable batteries or other appropriate energy storage device would also be applicable. The battery  410  would include a built in battery management system  414  for managing charging and output of the battery  410 . 
         [0027]    An alternative implementation of the smart battery pack  102  separates the front user interface that is shown in  FIGS. 2  from the smart battery pack  102  while maintaining the power and control connector  302  at the back as shown in  FIGS. 3 . The separated user interface module houses all, but not limited to, the interfaces shown in  FIGS. 2  while also equipped with the power and control connector  302  to interface with the smart battery pack  102 . In this implementation, both utilizing and replenishing the charge in smart battery pack  102  are not directly available. Both actions require the smart battery pack  102  to be connected to rack  104  or a User Interface module  1101  as shown in  FIG. 4B . 
         [0028]    Referring to  FIG. 4B , a user interface module  1101  consists of, but is not limited to 110V/220V AC input, 15 VDC or higher DC input, high power USB output, 12V/24V DC output with various connector option such as DC plug, Anderson connector etc. The user interface module  1101  can be connected to a single or multiple smart battery packs  102  depending on the power requirements. To provide AC output, an inverter module  1102  can be connected. The tracking solar panel module  1103  consists of a solar cell array  1104  and sun tracking mechanism  1106  that always ensure that the solar panel is facing the sun, thus, working at its maximum efficiency.  FIG. 4B  shows how the functional modular unit is connected to provide a portable solar generator solution. The tracking PV panel module  1103  can be a waterproof suitcase design that comes with multiple compartments for housing the functional modular unit. The attachment between modules can either be a permanent fixed attachment or a detachable click or lock design. The functional modular unit is not limited to only what is shown in  FIG. 4B . It can be further extended to cater to different lifestyle needs such as Wi-Fi router module, emergency lighting modules, portable speaker module, wireless charging module, etc. 
         [0029]    Referring now to  FIGS. 5 and 6 , there is illustrated a rack  502  configured to receive a plurality of smart battery packs  102  such that the battery packs  102  may be charged and the combined power outputs of the battery packs  102  may be combined into one or more outputs for powering higher power rated electrical loads.  FIG. 5  illustrates a front view of the rack  502  while  FIG. 6  illustrates the rear view. The rack  502  includes slots for containing up to seven battery packs  102 . While the present configuration includes slots for receiving seven battery packs  102 , configurations for a greater or lesser number of battery packs  102  are also possible. The rack  502  enables a user to use a single rack  502  to charge multiple battery packs  102 . Once a battery pack is charged, it may be removed and another uncharged battery pack inserted into the rack  502 . The battery packs  102  slide into the rack  502  on rails  504  locates on each side  506  of the rack  502 . The battery packs  102  when inserted within the rack  502  on the rails  504  engage a power control termination point  404  with the power and control connector  302  of the battery pack  102 . The power control termination point  404  enables the output power from the battery  410  within the battery pack  102  to be pooled together with power provided by other battery packs. Additionally, the power and control connector  302  provides interconnection with battery pack control circuits  602 . Additionally, the user device interface  604  enables combined control of each of the battery packs  102  within a rack  502 . 
         [0030]    The rack  502  may have considerable weight associated therewith. Thus, in order to facilitate movement of the rack  502 , a number of wheels or tracks  608  could be placed under the rack  502  to enable ease of movement. Additionally, a trolley power mechanism may also be utilized as more particularly illustrated in  FIG. 7 . Within the trolley-mounted mechanism a drive train  702  provides driven wheels or tracks  608  moving the rack  502  from one location to the other. The drive train  702  is powered by an electric motor  704  that drives the drive train  702 . The motor  704  may be powered by the battery packs  102  within the rack  502 . The trolley mechanism may additionally include user control  706  which enables the user to control the speed of the motor  704  and the operation of the drive train  702  in order to enable a user to drive or control movement of the rack  502  from one location to another. In alternative embodiments, the trolley mechanism might also include a standing platform enabling a user to ride with the rack  502  as the rack moves. 
         [0031]    Referring now to  FIG. 8 , there is illustrated a functional block diagram of the interconnection between the power control termination point  404  on the back of each of the battery packs  102  within a rack  502  and its associated smart battery pack control circuit  602  associated with the rack  502 . The smart battery pack control circuits  602  enable individual control of a battery pack  102  that is interconnected with the smart battery pack control circuits  602  through the power control termination point  404 . The smart battery pack control circuits  602  manages the flow of current to and from the individual battery packs  102  as well as the polarity of connections of the individual battery packs. The smart battery pack control circuits  602  interconnect with the user device interface  604 , which manages the connectivity of the circuits on the premises where the rack  502  is being utilized and connects the appropriate circuit breakers and control electronics to control the flow of electricity between the rack  502  and the circuits on a customer&#39;s premises. 
         [0032]    A user device interface  604  enables pooled control of each of the battery packs  102  through the associated smart battery pack control circuits  602 . User control inputs  802  are provided to the user device interface  604  to enable the power associated with each of the battery packs  102  within an associated rack  502  to be controlled in a desired manner. Implementation of the user control input  802  may be configured such that the user control input  802  can be effected remotely by means of communication medium (such as Wi-Fi or Internet), thus, allowing remote control and monitoring by user. The user device interface  604  may provide one or more outputs  804 . The user device interface  604  may be configured by the user control inputs  802  such that each output  804  of the user device interface  604  goes to a separate connected electrical load. Alternatively, the user device interface  604  may pool together all or a portion of the power provided from individual battery packs  102  to provide power to higher power requiring loads. By pooling the power outputs from individual battery packs  102 , the rack may obtain higher power capacity for various high power devices such as a microwave oven, refrigerator, dryer, washer, etc. 
         [0033]    The user control inputs  802  enable the user to define the number of battery packs  102  that support the power needs of a specific circuit via the user device interface  604  which controls the smart battery pack control circuits  602  of battery pack  102 . Thus, a varying number of battery packs  102  may be used to match the power needs of different premises circuit loads such as that for a washer/dryer, a refrigerator, etc. Additionally, one or more battery packs  102  may be taken out of service as a power backup element and removed to perform duties as a portable power source with various power outlets presented as a user interface without affecting the utility of the rack other than the reduction of power associated with the removal of the battery pack or packs. Thus, the battery packs  102  may be deployed as an off-grid automatic or manual power backup for the customer premises. 
         [0034]    In addition to pooling power sources from multiple battery packs  102  within a single rack  502 , the power providing services of multiple racks  502  may be pooled together to provide even greater power backup resources to a customer as more particularly illustrated in  FIG. 9 . Each rack  502  comprises an independent module comprising a varying number of battery packs  102 . Several battery racks  502  or groups of such racks may be combined or pooled together to provide an aggregate power source of greater power and/or different voltage configurations by providing outputs and control from each of the rack  502  to a group rack control  902  via the user device interface  604  of each of the associated racks  502 . The group rack control  502  connects to a customer utility interface  904  to provide connection to various load circuits on the customer&#39;s premises. 
         [0035]      FIG. 9  illustrates (N) number of racks each of which is provisioned with five battery packs  102  but which may be provisioned with up to seven battery packs in this example. If each battery pack  102  provides 250 watt-hours of power, each fully provisioned rack  502  can provide a battery storage capacity of 1750 watt-hours. Thus, the four racks  502  would provide an aggregate power of 7,000 watt-hours to a customer&#39;s premises providing temporary backup for a typical home while enabling the customer to remove several battery packs  102  for internal or external use as portable power sources within or outside the premise. Since each rack  502  may be affixed to trolleys or equipped with wheels, each fully provisioned rack in the example may be used as a 1750 watt-hour portable electrical generator. 
         [0036]    The group rack control  902  is a smart programmable controller that can automatically detect when a rack  502  is actively available to provide power. The group rack control  902  may also detect the number of battery packs  102  that are provisioned within a particular rack  502 . As battery packs  102  are removed and used in other portable situations, some battery packs may require recharging time before they can be placed into service to provide power to the group rack control  902 . Additionally, the group rack control  902  may generate control signals to activate or deactivate any battery pack  102  within a rack  502  so as to isolate the specific battery pack from active pooling duty. The group rack control  902  may also be programmed to selectively pool specific battery packs  102  and/or racks  502  for duty and to connect specific load circuits to specific battery packs and/or racks to prioritize the availability of power service to specific load circuits. Thus, various different loads such as a freezer, which requires uninterrupted power, may be accorded priority of service before a washer/dryer on a separate load circuit. The functionality of the group rack control  902  and other elements depicted in  FIG. 9  may be distributed and designed into other elements of the modular customer premises grid power backup system. 
         [0037]    Referring now to  FIG. 10 , there is provided one example of a design implementation of the system of  FIG. 9 . The configuration illustrates a rack  502  or system of racks  502  that are powered by deploying photovoltaic panels  1002  or other alternative power sources to the premises with controllers that automatically switch between the grid electricity and alternative power sources to provide charging power to the battery packs  102  and racks  502 . This option is depicted with a set of photovoltaic panels  1002  as the alternative power source. Each rack  502  converts to a photovoltaic panel assembly  102  whereupon the maximum power point transfer (MPPT) control element  1004  may be incorporated into the rack  502  rather than as a separate component. In the configuration of  FIG. 10 , the photovoltaic panels  1002  interconnect with the maximum power point transfer charger  1004 . These panels may be of different output voltage configurations. The maximum power point transfer charger  1004  provides a charging power to each of the racks  502  through a maximum power point transfer input  1006 . An AC charging input  1008  provides charging power to each of the racks  502  through associated AC to DC convertors  1010  within each of the racks  502 . 
         [0038]    A charging disconnect control circuit  1012  provides either the charging power provided from the photovoltaic panels  1002  or the AC input  1008  depending on which of these is currently available. The provided charging power from the charging disconnect control circuitry  1012  goes to charging and control circuitry  1014  within the rack  502  to provide the charging power to the various battery packs  102  placed within the rack  502 . Each of the charged battery packs  102  provides power from its batteries to the associated battery pack control circuits  602 . Battery pack control circuits  602  which then forward this power onto the user device interface  604  as described previously. The pooled output from the each individual racks  502  is provided to the group rack control  902  via connections to rack pooling interfaces  1016  within the group rack control  902 . A connection may be established between the group rack control  902  and the customer utility interface  904  to provide power to the customer premises as necessary. 
         [0039]    It will be appreciated by those skilled in the art having the benefit of this disclosure that using the above described modular power backup system, various levels of battery backup may be provided at a customer&#39;s premises. The customer may select and provide the amount of battery backup as desired depending upon a number of utilized battery packs and/or battery racks in order to configure their backup needs in a desired manner. It should be understood that the drawings and detailed description herein are to be regarded in an illustrative rather than a restrictive manner, and are not intended to be limiting to the particular forms and examples disclosed. On the contrary, included are any further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments apparent to those of ordinary skill in the art, without departing from the spirit and scope hereof, as defined by the following claims. Thus, it is intended that the following claims be interpreted to embrace all such further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments.