Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims priority to and is a continuation-in-part of U.S. patent application Ser. No. 10/631,017, filed on Jul. 31, 2003, the entire contents of which are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to electrical energy storage systems and, in particular, to battery packs composed of multiple battery modules with adjustable configurations.  
         [0004]     2. Description of the Related Art  
         [0005]     Hybrid electric vehicles (HEVs), hybrid electric ships and boats (such as the QE2) afford greater fuel efficiency than vehicles or vessels having only a prime mover (e.g., diesel or gasoline engine, gas turbine and fuel cell). Greater efficiency is obtained by using an energy store to level the load on the prime mover-providing peaking power to an electric motor, or storing energy during low power prime mover operation or during regenerative braking.  
         [0006]     A well-developed form of energy storage for this application is a battery pack, and there are several candidate battery chemistry systems that may be utilized. Of these systems, the lithium-ion (Li-ion) technology is the most energy and power dense. Li-ion cell technology for this application is currently capable of energy density of up to 134 W-hr (482 kJ) per kg (HE40 cell), and a power density of up to 13 kW per kg (e.g., HP18650 cell short duration, manufactured by SAFT AMERICA).  
         [0007]     Vehicle battery packs sized for multiple military combat missions, (such as the Combat Hybrid Power Systems (CHPS) Systems Integration Lab (SIL) battery pack) store approximately 108 MJ (30 kW-hr). If the highest power density SAFT cells (HP18650) are utilized, then the short duration power capability of the battery pack would be greater than 4 MW.  
         [0008]     Such a peak power capability could enhance both offensive and defensive capabilities if it were easily convertible to voltages commensurate with a range of potential short-term and pulsed loads. For example, Electromagnetic Armor (EMA) provides lightweight protection to combat vehicles against rocket-propelled grenade attacks. The energy required for the EMA to function is stored in a fast discharge capacitor bank, which is recharged either from a generator operated by the prime mover of the vehicle, or from an intermediate energy storage system. In a HEV, the electric energy battery pack also could function as such an intermediate energy storage system. However, in order to provide the approximately 10 kV needed as the input voltage to the capacitor bank, a DC-DC power converter is needed between the intermediate energy storage system and the capacitor bank.  
         [0009]     The traditional methods for DC-DC power conversion typically involve the use of inverters and heavy-duty transformers. Current EMA designs require approximately 150 kJ to recharge the capacitor bank. At 3 pulses per second (pps) operation, even for a short period of time, the recharge time would have to be on the order of 300 ms. Consequently, the recharge power would have to be on the order of 500 kW average, or 1 MW peak. However, a 1 MW peak power traditional DC-DC converter, using present technology, would add more volume and mass to the vehicle platform than is allowable in a 16-20 ton class vehicle.  
         [0010]     Thus, there exists a need in the art for a system power density improvement in producing short term high power at high voltages from a battery pack normally configured to provide hybrid vehicle prime mover load leveling and/or silent mobility capability or in other fixed or moving battery platforms such as battery backpack systems or pulsed energy weapons or launch systems.  
       SUMMARY OF THE INVENTION  
       [0011]     The present invention provides an alternative method for converting DC from bus voltage to a voltage that is compatible with various loads. According to the present invention, a battery pack is electronically re-configured to produce multiples of a bus voltage, momentarily and on command. Such a battery pack would be configured in modules that are equal to the power distribution bus voltage. The entire battery pack, or some fraction thereof, can be erected and de-erected on command, analogous to the operation of a Marx generator (commonly used for capacitive voltage multiplication).  
         [0012]     According to embodiments of the present invention, the need for intermediate DC-DC power conversion circuitry is reduced or eliminated by using electronic switching to convert the battery pack modules from their normal parallel configuration for vehicle or ship load leveling and/or silent mobility functions, to a series configuration that is capable of delivering the necessary high power and high voltage output for short-term and pulsed load operations.  
         [0013]     In particular, according to a first preferred embodiment, the present invention provides an electronically reconfigurable battery, including a first number of battery modules, a number of switches selectively interconnecting the battery modules, wherein a selectable number of the battery modules may be connected either in a series configuration or in a parallel configuration, as a result of placing selected switches of the switches in open states or closed states, and an output switch connecting a first output terminal of the battery to a first load. DC current flow is limited and controlled by electrochemical DC current discharge characteristics of the battery technology used, such as in the case of lithium-ion (Li-ion) technology.  
         [0014]     In another embodiment of the present invention, an electronically reconfigurable battery includes a first number of battery modules, a number of switches selectively interconnecting the battery modules, and a current limiting section or a current limiting DC-DC converter, wherein a selectable number of the battery modules may be connected either in a series configuration or in a parallel configuration, as a result of placing selected ones of the switches in open states or in closed states, and an output switch connecting a first output terminal of the battery to a first load.  
         [0015]     The DC current limiting device can be used to control the current outside the range of the electrochemical DC current discharge characteristics of the battery technology used. A parallel operation DC by-pass switch is optionally incorporated within the current limiting section dependent on the technology used and where the section is located at the beginning or end of the series connected batteries. A simple example of this current limiting section is a series connected power resistor, or inductor connected in series between the high voltage battery end terminal and a Pulse Forming Network capacitor bank (commonly known as a PFN capacitor) forming the resistive, the inductive or resonant capacitor charging circuit.  
         [0016]     According to another embodiment of the present invention, an electronically reconfigurable battery includes a first number of battery modules, a number of switches selectively interconnecting the battery modules, a single stage current limiting section or a single stage current limiting DC-DC converter (hereinafter referred to as a single stage converter or SSC). The SSC may take the form of a resistor or inductor or a reduced size electronic DC-DC converter using some form of Buck, Boost, Buck/Boost or Resonate or inductive converter topology, wherein a selectable number of the battery modules may be connected either in a sequential series configuration operation or in a parallel configuration, as a result of placing selected switches of the switches in open states or closed states, and an output switch connecting a first output terminal of the battery to a first load.  
         [0017]     A DC current limiting device can be used to control the current outside the range of the electrochemical DC current discharge characteristics of the battery technology used. A parallel operation DC by-pass switch is optionally incorporated within the current limiting section dependent on the technology used and whether the section is located at the beginning, end or middle of the series connected batteries.  
         [0018]     According to another embodiment of the present invention, the system may be configured to be redundant and fault tolerant in most applications and is capable of bidirectional power flow. Additionally, the system can be built in either a discrete or stackable modular form. The system may include one or more voltage scalable arms that are configured in a “star” or “H” configuration with switch steering matrixes both in the inner and outer portions of the star configurations. These switching arrays can also be used to cross-connect multiple star configurations and isolate the loads from the ERB sections. The multiple arms may be connected at one end for the parallel Low voltage or Baseline Voltage operation using inner (base) switch matrix or direct hardwired connected between the multiple arms. The other end of each arm is connected to the Series or variable high voltage (VHV) connection. The energy from the base side connection of each arm is fed in parallel to the center switch matrix primarily to provide traction power or the main system load. This voltage is normally fixed at the module&#39;s base voltage level. The Energy stored in the arm can also be directed to flow out the opposite end of the each arm through the VHV connection into an outer switch matrix or multiple outer switch matrixes at different voltage levels that connects to auxiliary loads or pulse power loads. The Energy flow is in discrete energy packets that are time multiplexed on the VHV connection side while maintaining a continuous connection and energy flow through the base or parallel connection side. The modules can be erected and de-erected at high speed in series and parallel combinations allowing the VHV output to be continuous, or rising stair case step voltage or a pulsed voltage and energy output. Thus, the VHV output connection is allowed to charge and transfer energy from the base voltage energy storage system through the VHV steering matrices to much higher voltage energy storage systems located at or near the auxiliary high voltage loads.  
         [0019]     Each arm may be composed of a group of smart reconfigurable identical energy modules that each contain, in the least: a base power source, such as 720 Volt battery stack; a stackable intermediate pass-through switch matrix; an  
         [0020]     inter-module interconnect bus bar system; protection systems; and a distributed control system. The modules in each arm can be electronically reconfigured themselves to connect in parallel to the parallel inner bus structure at the base voltage or to be disconnected from the parallel inner bus structure. Additionally, the modules can be configured to transfer and redirect energy out of the VHV connection into the multiple output switch or output steering matrixes to the auxiliary HV energy stores by and raising the voltage and pulsing the energy out of the VHV connection.  
         [0021]     The energy packets can be controlled in two dimensions: discrete voltage steps and time. The variable voltage has discrete voltage steps that are the same voltage level as the individual module stages; the number of steps is determined by the number of modules. The VHV voltage can be raised to the value of the base voltage multiplied by the number of modules in the arm connected in series. Each module can have two high power input and two high power output connections, a digital communication port or ports, and an auxiliary power input.  
         [0022]     Notably, this system is substantially different from other reconfigurable battery or energy sources in that the series parallel switch matrix and bus bars are an integral part of the module and it can function as a “plug and play” system with modules in parallel mode of operation with two arms in parallel as clearly detailed in  FIG. 8 . That is, any of the modular diagrams  FIGS. 1-6  can be used in  FIG. 7  or  8  configurations.  FIGS. 1-6  also show only the positive output version of the arm connections. For negative output arm connection simply the input and output connection are reversed as shown in detail H configuration  FIG. 8  and move the current limiting or active conditioning systems as shown in  FIGS. 2-5  to the opposite end.  
         [0023]     For positive output, the base or the parallel input shown in  FIGS. 7-8  are the same input or low voltage parallel connection as static store connections ( 207 ) of  FIG. 2 . Vehicle mobility battery and loads as shown in  FIG. 3 . Static store ( 442 ) in  FIG. 4 . the static store connection of  FIGS. 5 and 6   
         [0024]     Each of the single arm configurations shown in  FIGS. 1-6  have a single diode HV matrix switch, labeled D 1  built into the end module the diode located in the last module and at the end of the High voltage chain or arm. The connection at cathode end of the diode is the normal HV output. In  FIG. 8-9 , and the diode matrix is external to the modules, resulting in identical modules.  
         [0025]     Thus, the maximum voltage can be changed by adding or subtracting plug in module without any bus bar or switch matrix changes. For example, a four arm “star” configuration—the “H” configuration—has one end of each arm connected in parallel at the center of the star connected to the 720 volt traction drive system and four outer ends of the arms creating two +5.7 Kilovolt variable voltage sources and two −5.7 Kilovolt sources. The outer steering switch matrix in this case can include 4 high voltage diodes and two pairs of arms are essential in parallel for redundancy for continued operation after sustaining faults or battle damage. The 11.4 kV (kilovolt) differential voltages are used to charge a 150 kJ pulsed power 10 kV capacitor bank. Each arm consists of 8 modules which translates to 32 (i.e. 8×2×2) modules in parallel operation. When used in a high performance traction drive, the energy packets can be time multiplexed between the drive system and erecting the 11.4 Kv pulsed power system. Total elapsed time for charging the capacitor bank is under 500 milliseconds.  
         [0026]     In a more complex embodiment, with additional arms and sophisticated output load switch matrix added, energy packets can deliver energy to loads between 720 and 5.7 kV. Using the same modules, the system is scaled up to a 30 kV pulsed power application by simply adding more modules in series.  
         [0027]     There are several differences between this system and other reconfigurable battery systems that have been around since the first battery powered trucks and cars. First, this system is designed for at least two output or loads that have different voltage requirements. Second, this topology is based on a “Star or H” Configuration with multiple reconfigurable energy storage and production arms with multiple time multiplexed outputs. Finally, there is an inner and outer switch matrix for controlling and directing the voltage and energy an intermediate switch matrix that is distributed among the modules each module contains the battery pack or energy source, the switch gear and bus work.  
         [0028]     This more complex reconfigurable electrical energy storage system is especially useful in hybrid electric vehicles, ships, or boats (i.e., vehicles, ships, or boats powered by both a prime mover and an electrical energy power source) used in military operations and in other fixed or moving platforms where it is desirable to be able to redirect and level shift the stored energy in the reconfigurable electrical energy storage system to auxiliary higher voltage energy storage and deliver systems such as pulsed power weapon and protection systems. Examples of such reconfigurations include a shift from a low voltage parallel configuration to high voltage series/parallel configurations for optimizing impedance match, minimizing or eliminating the need for an associated power converter for pulsed power applications, powering other subsystems or matching variable DC link main systems as envisioned in, for instance, the original CHPS combat hybrid vehicle, which shifted from a 300-400V low voltage parade voltage to a higher 900-1200V combat status bus voltage.  
         [0029]     Another embodiment of the present invention employs a modular scalable electric power distribution topology having multiple outputs to transfer energy and power between loads and sources of different operating voltages simultaneously. This transfer can occur in either a continuous or time multiplexed manner consisting of one or more reconfigurable energy storage or production ERB arms connected in the ““star or H”” configuration. Each of the two ends of an ERB arm has a bidirectional power output connection referred to as the base or parallel output connection and the high variable high voltage (VHV) output connection.  
         [0030]     Three switch or steering matrix arrays can be used for directing and controlling the energy flow. The first array includes an inner or base switching array located at the center of the star configuration for parallel combinations of the parallel or base voltage. The second array includes an intermediate switching matrix array distributed along each arm in the modular sections for parallel and series module combinations. The third array includes an output matrix or steering array or arrays to direct the VHV output from each ERB arm. The VHV array connects the multiple arms of the VHV outputs to the various multiple auxiliary storage systems or loads at voltages higher than the center base voltage.  
         [0031]     Each energy storage or production ERB arm consists of a building block modular system in discrete or modular form consisting of multiple identical interface modules. The ERB modules contain an energy storage device such as a battery or capacitor or an energy production or transformation module such as a fuel cell or a power conversion device such as a solid state converter as shown in the text body. Additionally, each ERB module contains a piece of the distributed modular intermediate bus structure and switch matrix steering array as well as a part of the distributed control system and algorithms to prevent faults, misconnections and catastrophic failures due to mistiming of switch elements.  
         [0032]     Another embodiment of the present invention may employ a method of transferring energy from one voltage and intermediate energy storage or energy production system to a higher or lower voltage energy storage system or load.  
         [0033]     Another embodiment employs a simple switching algorithm and a three switch and one diode configuration that guarantees no catastrophic battery or fire failures due to mistiming of the in high speed switching or modulating of the series connection switches in the intermediated switch array. This is accomplished by switching off or opening all of the positive and negative rail switches rail switches labeled P and N in simplified parallel operation diagram, then using just the one series switch connection labeled S and one Required steering diodes per module allows seamless high speed erecting and de-erecting of the batteries or capacitors in series or series voltage stepped VHV Output by selecting the number of series switches turned on or sequenced with no critical timing issues.  
         [0034]     In another embodiment the base switch matrix can be effectively set to ‘ON’ at all times by replacing the switch matrix with hard wired parallel connections of the base voltage terminals of the ERB Arms. One notable improvement of this invention over the prior art is that it allows simple scaling of more by the simple addition of more modules without any rewiring due to its modular and scalar design. Sophisticated ERB systems with complete redundancy of the ERB star and multiple star configurations are easily configured by switched in and cross connected at the base and/or at the VHV level matrix levels.  
         [0035]     In an alternative embodiment, VHV outputs can be steered in parallel operation through a simple VHV diode steering array. This allows complete or partial failure of one more ERB arms without rendering the system inoperative. Two sets of two arms each supply energy in parallel to the 10 Kv 150 kJ energy storage capacitor. As a result, the system can suffer a complete failure of one plus and one minus output ERB arm and still meet VHV mission requirements. Furthermore, the system can suffer the loss of three ERB arms before losing traction or moving capability. A multiple arms configuration, such as the “star” or “H”, is a great improvement over the single arm ERB configuration because parallel operation battery source resistance or ESR (Equivalent series resistance) is reduced by a factor of 4, or the number of arms in parallel.  
         [0036]     In an alternative embodiment the ERB module can be “plug and play”. In this form, the module consists of a stand alone self contained module with simple power two input port connections and two output power connections. The energy source, part of the modular distributed series and parallel switch matrix and bus bar system, fusing and protection and control system are all internal to the module. The Power ports can be directly connected to another module. In each ERB arm, first designated module input ports are connected to the base or parallel operation bus or matrix. The output of the first module is connected to the input of the second module in the module string in the ERB arm continuing in this fashion until the last module in the string is connected and the output port connection now become the VHV connection to the VHV steering array. Very high voltages can be achieved in this fashion, and 30-40 kv systems can be designed using this building block approach. Because of its scalability, the number of modules per ERB arm is application driven and, in a multiple arm ERM “star” configuration system, each arm may have a different number of modules and have a different polarization an output voltage to satisfy a wide variety of load requirements.  
         [0037]     In another embodiment nested ERB are used. Nested, or layered, ERB are ERB systems with nested or layered ERB are contained within each level of stackable modules. The next level of ERB is to use an ERB within the ERB module to reduce the base voltage and basic module voltage. An example is reducing a 720 volts ERB module to a lower voltage 36 volts ERB module using ten (10) sub ERB modules within each 720 volt ERB module. The advantage is it allows the Base voltage to be dropped and allows a finer resolution in the high voltage output example 10 sub modules×8 modules=80 voltage steps resolution in the VHV output. This allows the Base current in parallel operation to be teri times higher for high torque low speed application or to create long life parade ground low voltage power and shorter life high speed combat modes.  
         [0038]     The reconfigurable electrical energy storage system may combine one or all one or all of the above-mentioned features.  
         [0039]     Further applications and advantages of various embodiments of the present invention are discussed below with reference to the drawing Figs. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0040]      FIG. 1  is a block diagram of a hybrid electric vehicle platform power distribution system including an electronically reconfigurable battery according to an embodiment of the present invention;  
         [0041]      FIG. 2  is a schematic diagram of an electronically reconfigurable battery according to an embodiment of the present invention, adapted for use with an electromagnetic armor (EMA) system for a combat hybrid electric vehicle and other platforms;  
         [0042]      FIG. 3  is a schematic diagram of an electronically reconfigurable battery according to an embodiment of the present invention, adapted to a generic use;  
         [0043]      FIG. 4  is a schematic diagram of an electronically reconfigurable battery including a current limiting section according to an embodiment of the present invention, adapted for use with an electromagnetic armor (EMA) system for a combat hybrid electric vehicle and other platforms;  
         [0044]      FIG. 5  is a schematic diagram of an electronically reconfigurable battery including a single stage converter (SSC) according to an embodiment of the present invention, adapted for use with an electromagnetic armor (EMA), ETC Gun, pulsed laser, pulsed beam, energy or particle source systems for a combat hybrid electric vehicle and other platforms;  
         [0045]      FIG. 6  is a schematic diagram of an electronically reconfigurable battery including a single stage buck/boost converter section (SSC) according to an embodiment of the present invention, for use with an electromagnetic armor (EMA), ETC Gun, pulsed laser, pulsed beam, energy or particle source systems for a combat hybrid electric vehicle and other platforms.  
         [0046]      FIG. 7  is a schematic diagram of a simplified “H” or “star” configuration ERB system according to an embodiment of the present invention.  
         [0047]      FIG. 8  is an illustration of an “H” configuration ERB system according to an embodiment of the present invention.  
         [0048]      FIG. 9  is a schematic view of a scalable ERB arm for use in an “H” or “star” configuration ERB system according to an embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0049]     The term “star” configuration refers to novel battery configurations having 2 or more battery arms, which will be understood from the description below and the drawing figures. The “H” configuration refers to a “star” configuration with only 4 arms and is a subset of star configurations. Star configurations are not limited in the number of arms they can have.  
         [0050]     Dependent on the system configuration, common modules can be configured into multiple arms with positive or negative high voltage output with High Voltage Steering diode or HV Steering diode switch matrixes and with one or multiple inner starring and disconnect switch matrixes surrounding common hub parallel connection.  
         [0051]     For simplicity sake,  FIGS. 7-8  show a star configuration with 4 arms or chains of strings of modules depicted in  FIGS. 1-6 . However, the number of arms in these exemplary star configurations could have been 8, 9 or 10 arms or higher. In fact, it is contemplated that the present invention could be implemented with 1000 or more arms.  
         [0052]     As shown in  FIG. 1 , a hybrid vehicle platform power distribution system  100  includes a prime mover  101  (e.g., diesel engine, gas turbine, fuel cell, etc.) coupled to the vehicle transmission (gears)  102 , and an n-phase electric motor  103  coupled directly to the drive wheels of the vehicle  109 . The gears also are coupled to a generator  104  for recharging the electrical energy storage (ERB energy store)  105 , for example, during regenerative vehicle braking and during low power prime mover operation. The ERB energy store  105  functions to power the n-phase motor  103  for vehicle load leveling and/or silent mobility operation, and also is used to provide power to various short-term and pulsed load devices  106 . Power electronic circuitry  107  controls the reconfiguration of the ERB, the interfacing between the generator  104 , motor  103 , ERB store  105 , and short-term and pulsed loads  106 , as well as providing appropriate bus voltage to a voltage bus (hotel bus)  108 .  
         [0053]     As shown in  FIG. 2 , an electronically reconfigurable battery  200  according to the first embodiment of the invention includes a number of battery modules  201 . An example of such a battery module is an Ultralife® lithium polymer rechargeable battery module (e.g., UBC44 or UBC38). Other candidate modules include, but are not limited to, SAFT HP cells (such as HP 12, HP 6, and HP 18650).  
         [0054]     The battery  210  includes a number of modules that are permanently configured in parallel with each other (static store)  207  and connected to the vehicle load bus  211 , which powers the electric motor. Other modules (dynamic store)  208  can be switched between parallel configuration to support the vehicle load bus  211 , and a series configuration to charge the EMA capacitor bank  209  (or other short-term or pulsed load not shown). The electronic reconfiguration of the dynamic store modules  208  requires three switches per module.  
         [0055]     An erectable battery module  201  is associated with battery isolation switches  202  and  203 , and a series switch  204 . All switches (with the exception of the output switch  205 ) need only block the voltage of a single battery module and open at near zero current (for capacitor charging) in normal operation. Transient conditions during erection and de-erection are controlled by passive snubbing. Reconfiguration can be accomplished in less than 1 ms using standard off-the-shelf solid state switches such as integrated gate bipolar transistors (IGBT) or Metal Oxide Field Effect Transistors (MOSFET).  
         [0056]     Switches  202 ,  203 , and  204  can be rated for the module voltage (such as 1 kV) only. Switch  205  is an output switch that is rated for the full output of the ERB (e.g., 10 kV and 100 amps), and can be implemented as a series stack of the same switches used for switches  202 ,  203 , and  204 . A vacuum contactor  212  and fuse  213  are placed in series with the output switch  205  to provide fault protection and charge interrupt. All switches are preferably opto-isolated, with gate power drawn from their associated adjacent battery modules. Switch  206  is high-voltage high-current closing switch, and can be either a vacuum switch or a solid state switch. Switch  206  discharges the EMA capacitor bank into the EMA load.  
         [0057]     With some 8,000 cells necessary to make up a 30 kW-hr vehicle battery pack, voltages would be available in multiples of the distribution bus voltage up to 30 kV. Furthermore, each of these voltage levels is available with the full power capability of the battery pack. Construction techniques used in the HP18650 are scaleable to larger or smaller individual cells so that optimization for the particular application is possible.  
       EXAMPLE  
       [0058]     Assuming a 20-ton class vehicle and extrapolating from CHPS requirements, a conceptual design of an ERB for a hybrid electric vehicle with an EMA system has the following requirements: 1) Deliver up to 400 kW to the vehicle bus at 1 kV in parallel operation; 2) Recharge a 150-kJ capacitive store to 10 kV in 300 milliseconds; and 3) Support 30-45 minute silent operation at 80 kW. These requirements mandate the use of very high energy and power density batteries. Two candidate batteries are the HP series of lithium ion batteries being developed by SAFT and the lithium polymer batteries produced by Ultralife Batteries, Inc. for use in cell phones. The SAFT batteries have a slight advantage in usable power density and packaging for military use, whereas the Ultralife batteries have an advantage in cost (0.15-0.2 cents/J, 5-8 cents/Wpk, owing to volume production) and a potential for more compact packaging (prismatic) in ERB service.  
         [0059]     The ERB system in this case constitutes only ⅓ of the total battery for erected (dynamic) operation. The remaining ⅔ of the store (static) is dedicated to load leveling and silent mobility. The total capacity of ˜290 MJ (80 kW-hr) accommodates silent mobility requirements. With only ⅓ (90 MJ, 25 kW-hr) of the total capacity configured for on-command electronic erection and de-erection, the vehicle energy storage system maintains its load leveling and silent operation capability even when the EMA is active.  
         [0060]     54 series×7 parallel Ultralife Model UBC44106102 polymer batteries are assembled into 200-volt stacks (378 cells per pack), in the static store. Five of these packs are placed in series to obtain an output voltage equal to that of the vehicle bus and constitute a module. Two such modules in parallel make up the static store (3780 cells total). In the dynamic portion of the store, the UBC383562 cell is used because of its heavier tabbing and proven current capability. The 200-volt packs in this case consist of 54 series×4 parallel cells (216 total). Five such packs make up an erectable module and there are 10 modules, thus providing 10 kV on command for EMA store charging (approximately 90 MJ; 10,800 total cells). A dynamic module will incorporate all necessary switches, isolation and thermal management hardware. The total battery volume in the static store is approximately 0.18 m3 and the accessories are expected to add another 0.135 m3 for a total volume of approximately 0.315 m3 and a mass of 620 kg. The dynamic store is less efficient volumetrically, because for the need to insulate for the 10 kV momentary operation and thermal stress associated with MW-class power for even a few seconds. We expect a battery volume of 0.089 m3 with a total of volume of 0.314 m3 and a mass of 500 kg, when accessories are included, for the dynamic store. These total to a volume of 0.629 m3 and mass of 1120 kg for the entire vehicle battery pack (˜300 MJ).  
         [0061]      FIG. 3  shows a generic application of the ERB system  300  according to an embodiment of the invention, wherein the ERB charges an energy store represented by a capacitor  330 , which is discharged via a switch  332  into a load represented by a resistor  334 .  
         [0062]      FIG. 4  shows another embodiment  400 , which has the same configuration as  FIG. 2 , with the PFN  440  represented by a block, and further including a current limiting device  441  inserted between the static  442  and dynamic  443  portions of the battery.  
         [0063]      FIG. 5  shows another embodiment  500 , which has the same configuration as  FIG. 4  except with a SSC  550  replacing the current limiting device, and diodes  551 ,  552  and  553  added as steering diodes. The charge sequence is different from the first and second embodiments, in that a sequential step charge mode of operation can be used with the circuit of  FIG. 5 , also the list of applicable loads is expanded and can be applied to all embodiments.  
         [0064]      FIG. 6  is an alternate example of another embodiment of the present invention. The ERB  600  is configured for a sequential step charge mode using a Buck/boost PWM single stage converter (SSC) type. The high-speed semiconductor switches U 1 , U 2  can be bipolar transistors, MOSFETs, IGBTS, SCR and other power semiconductor switches. Other converter types such as buck, boost and other electronic converter topologies are similar in operation and also can be used for the switching regulator.  
         [0065]     Example of Sequential Step Charge Operation  
         [0066]     The sequential step charging operation mode using a single stage converter (SSC) as shown in  FIGS. 5 and 6  is described below.  
         [0067]     The best location for the single stage converter  650  is between the static  660  and dynamic  670  portion of the battery as this limits the voltage stresses seen by the internal components, but the SSC  650  can be located anywhere within the series-connected loop that starts with the static store  660  portion of the battery and ends with the PFN capacitor bank  680 . A single inductor  651 , non-isolated buck/boost or interleaved buck/boost configuration is the preferred topology. A by-pass switch S 29  will normally be employed in this location to connect the dynamic portion  670  of the battery to the static portion  660  in a low loss manner, bypassing the SSC  650  in the parallel mode of operation.  
         [0068]     In the series sequential charge operation, the PFN capacitor bank  680  is charged in ten (10) sequential steps.  
         [0069]     First, the switches of the dynamic store portion  670  of the battery are all opened except for the positive isolation set of switches; the SSC  650  is now directly connected between the static portion  660  of the battery and the PFN capacitor  680 .  
         [0070]     Next the SSC  650  is turned “ON” and charges the PFN capacitor bank  680  at a controlled current (100A) to approximately slightly more (1010-1200V) than the single battery module voltage (1000V) at which point it shuts down momentarily and a battery module is erected in series with the SSC  650  by selectively opening and closing the appropriate switches. The SSC  650  is turned back “ON” and PFN capacitor bank  680  charges at the controlled current until the SSC  650  reaches its controlled output voltage set point at which time it will shut off again.  
         [0071]     The stored voltage in the PFN capacitor bank  680  is now V (SSC)+battery V 1  (2010-2200V).  
         [0072]     The cycle is repeated until all the batteries with the SSC  650  are erected in series, or the desired stored PFN voltage set point is reached (V PFN=(V (SSC)+batteries V 1 +V 2 +V 3 +V 4 +V 5 +V 6 +V 7 +V 8 +V 9 =(900-10200V)). By using this method the power processing capability required of the SSC  650  is reduced from the system level power delivered (10 kV@100A) by the number of battery stages erected plus one (in this case 10) for a (SSC) nominal power rating of 1000 v@100A or 100 kW. This reduces the converter size by a factor of more than ten because the converter has 1/10 of the voltage stresses and no longer needs an isolation or step-up transformer. PFN voltage regulation is finer and smoother than the first embodiment; however the first embodiment is the smallest physically, the most robust and is the cheapest to build.  
         [0073]     Normal Operation  
         [0074]     As shown in  FIGS. 5 and 6 , the dynamic part of the battery store is connected as nine parallel 1000 volt batteries (V 1 -V 9 ) connected in parallel with the main or static portion (V 10 -V 11 ) of the battery system. In normal operation, negative isolation switches S 3 , S 6 , S 9 , S 12 , S 15 , S 18 , S 21 , S 24 , S 27  and positive isolation switches S 2 , S 5 , S 8 , S 11 , S 14 , S 17 , S 20 , S 23  and S 26  are closed, and bypass switch S 29  in the SSC is closed. Battery series switches S 4 , S 7 , S 10 , S 13 , S 16 , S 19 , S 22 , S 25  and S 28  as well as HV contactor S 1  are open. The battery now has 11 parallel sections to power a vehicle.  
         [0075]     ERB Dynamic Operation  
         [0076]     The ERB dynamic section  670  is erected in 10 steps, which are now explained with reference to  FIG. 6 .  
         [0077]     Step one—Converting from Static to Dynamic mode and Single Stage converter (SSC) charging of the Pulse Forming Network (PFN) from 0 to 1200 volts  
         [0078]     The shift from static to dynamic operation begins with the SSC  650  bypass switch S 29  and all negative isolation and series connected switches being opened. All positive isolation switches are kept closed and HV contactor S 1  switches from being opened to closed.  
         [0079]     The SSC  650  then switches to a charge mode and begins charging the PFN storage capacitor bank  680  at an average current of 100 Amperes. The current flow path is through positive switches S 2 , S 5 , S 8 , S 11 , S 14 , S 17 , S 20 , S 23  and S 26 , which then forward bias diode D 1 , allowing the current to flow through HV contactor S 1  into the PFN capacitor bank  680 . At a PFN charge voltage of 1200 volts, the SSC  650  stops charging and goes into an idle mode for the Step 2 ERB configuration change. Current flowing into PFN stops and goes to zero.  
         [0080]     SSC Charge and Idle Modes of Operation  
         [0081]     In the charge mode of operation, for SSC  650  Voltage Output (Vout) range from zero to approximately 1000 volts, the SSC is in a step-down buck regulator mode with solid state high speed semiconductor switch U 2  open and solid state high speed semiconductor switch U 1  operating in a variable duty cycle Pulse Width Modulation (PWM) scheme to maintain an average output current of 100A (I out). For the Vout range from 1000-1200 volts, the SSC  650  shifts to a step-up boost mode and U 1  is now on at a 100% duty cycle, and U 2  is PWM modulated to control the output current.  
         [0082]     When Vout reaches 1200 volts, the SSC  650  is put in idle mode and U 2  is then turned on at 100% PWM and the SSC voltage output and current drop to zero. The loss of the SSC Vout of 1200 volts results in reverse biasing diode D 1  as the voltage difference between the PFN voltage and the dynamic store section is −1200 volts. The current flow through the dynamic store battery section  670  falls to zero due to the reverse biasing of Diode D 1 . Average current in the SSC&#39;s inductor is maintained by PWM modulating U 1  while U 2  is 100% on. At this point the process proceeds to step two.  
         [0083]     Step two—Erecting first battery stage-PFN charging voltage of 1200-2200 volts SSC starts the step 2 cycle in IDLE mode, Vout and Iout are at zero, negative switches S 3 , S 6 , S 9 , S 12 , S 15 , S 18 , S 21 , S 24 , and S 27  are open. Switch S 2  now opens and switch S 4  now closes, connecting battery V 1  in series with the SSC output. The SSC  650  now switches back to CHARGE mode and charges the PFN from 1200 volts to 2200 volts by the series voltage addition of SSC Vout and V 1  (1000V). Again Vout only varies over a range from 0-1200 Volts. At PFN charge voltage of 2200 volts, the SSC  650  goes back into IDLE mode for the Step 3 ERB configuration change.  
         [0084]     The amount of time needed for the SSC  650  to be in the IDLE mode is determined by the time required for the diode D 1  current to fall to zero and the time required to set the ERB switches to the new configuration. Total IDLE time per step change is estimated to be in the 10-100 microsecond range.  
         [0085]     Step 3—Erecting second battery stage-PFN voltage 2200-3200 volts: SSC starts step 3 cycle in IDLE mode, Vout and Iout are at zero, negative switches S 3 , S 6 , S 9 , S 12 , S 15 , S 18 , S 21 , S 24 , and S 27  are open. Switch S 2  is open and switch S 4  is closed. Switch S 5  is now opened and switch S 7  is now closed, connecting batteries V 1  and V 2  in series with the SSC output. The SSC  650  now switches back to CHARGE mode and charges the PFN from 2200 to 3200 volts by the series voltage addition of SSC Vout and V 1 , V 2  (2 kV). Again, Vout only varies over a range from 0-1200 volts. At PFN charge voltage of 3200 volts, the SSC goes back into IDLE mode for the Step 4 ERB configuration change.  
         [0086]     Step 4—Erecting Third battery stage-PFN voltage 3200-4200 volts: The SSC starts step 4 cycle in the IDLE mode, Vout and Iout are at zero, negative switches S 3 , S 6 , S 9 , S 12 , S 15 , S 18 , S 21 , S 24 , S 27  are open. Switches S 2 , S 5  are open and switches S 4 , S 7  are closed. Switch S 8  is now opened and switch S 10  is now closed, connecting batteries V 1 , V 2 , and V 3  in series with the SSC output.  
         [0087]     The SSC  650  now switches back to CHARGE mode and charges the PFN from 3200 to 4200 volts by the series voltage addition of SSC Vout and V 1 , V 2 , V 3  (3 kV). Vout varies over a range from 0-1200 volts. At PFN Charge voltage of 4.2 kV, the SSC goes back into IDLE mode for the Step 5 ERB configuration change.  
         [0088]     Step 5—Erecting Fourth battery stage-PFN voltage 4200-5200 volts: SSC starts step 5 cycle in IDLE mode, Vout and Iout are at zero, negative switches S 3 , S 6 , S 9 , S 12 , S 15 , S 18 , S 21 , S 24 , S 27  are open. Switches S 2 , S 5 , S 8  are open and switches S 4 , S 7 , S 10  are closed. Switch  14  is now opened and switch  16  is now closed, connecting batteries V 1 , V 2 , V 3 , and V 4  in series with the SSC output.  
         [0089]     The SSC  650  now switches back to CHARGE mode and charges the PFN from 4200 to 5200 volts by the series voltage addition of SSC Vout and V 1 , V 2 , V 3 , V 4  (4 kV). Vout varies over a range from 0-1200 volts. At PFN Charge voltage of 5200 Volts, the SSC goes back into IDLE mode for the Step 6 ERB configuration change.  
         [0090]     Step 6—Erecting Fifth battery stage-PFN voltage 5200-6200 volts: SSC  650  starts step 6 cycle in IDLE mode, Vout and Iout are at zero, negative switches S 3 , S 6 , S 9 , S 12 , S 15 , S 18 , S 21 , S 24 , S 27  are open. Switches S 2 , S 5 , S 8 , and S 11  are open and switches S 4 , S 7 , S 10 , and S 13  are closed. Switch  14  is now opened and switch  16  is now closed, connecting batteries V 1 , V 2 , V 3 , V 4 , and V 5  in series with the SSC output.  
         [0091]     The SSC  650  now switches back to CHARGE mode and charges the PFN from 5200 to 6200 volts by the series voltage addition of SSC Vout and V 1 , V 2 , V 3 , V 4 , V 5  (5 kV).  
         [0092]     Vout varies over a range from 0-1200 volts. At PFN Charge voltage of 6200 Volts, the SSC goes back into IDLE mode for the Step 7 ERB configuration change.  
         [0093]     Step 7—Erecting Sixth battery stage PFN voltage 6200-7200 volts: SSC  650  starts step 7 cycle in IDLE mode, Vout and Iout are at zero, negative switches S 3 , S 6 , S 9 , S 12 , S 15 , S 18 , S 21 , S 24 , S 27  are open. Switches S 2 , S 5 , S 8 , S 1  and S 14  are open and switches S 4 , S 7 , S 10 , S 13  and S 16  are closed. Switch  17  is now opened and switch  19  is now closed, connecting batteries V 1 , V 2 , V 3 , V 4 , V 5  and V 6  in series with the SSC output.  
         [0094]     The SSC  650  now switches back to CHARGE mode and charges the PFN from 6200 to 7200 volts by the series voltage addition of SSC Vout and V 1 , V 2 , V 3 , V 4 , V 5 , V 6  (6 kV).  
         [0095]     Vout varies over a range from 0-1200 volts. At PFN Charge voltage of 7200 Volts, the SSC goes back into IDLE mode for the Step 8 ERB configuration change.  
         [0096]     Step 8—Erecting Seventh battery stage PFN voltage 7200-8200 volts: SSC  650  starts step 8 cycle in IDLE mode, Vout and Iout are at zero, negative switches S 3 , S 6 , S 9 , S 12 , S 15 , S 18 , S 21 , S 24 , S 27  are open. Switches S 2 , S 5 , S 8 , S 11 , S 14  and S 17  are open and switches S 4 , S 7 , S 10 , S 13 , S 16  and S 19  are closed. Switch  20  is now opened and switch  22  is now closed, connecting batteries V 1 , V 2 , V 3 , V 4 , V 5 , V 6  and V 7  in series with the SSC output.  
         [0097]     The SSC  650  now switches back to CHARGE mode and charges the PFN from 7200 to 8200 volts by the series voltage addition of SSC Vout and V 1 , V 2 , V 3 , V 4 , V 5 , V 6 , V 7  (7 kV).  
         [0098]     Vout varies over a range from 0-1200 volts. At PFN Charge voltage of 8200 Volts, the SSC goes back into IDLE mode for the Step 9 ERB configuration change.  
         [0099]     Step 9—Erecting Eighth battery stage PFN voltage 8200-9200 volts: SSC  650  starts step 9 cycle in IDLE mode, Vout and Iout are at zero, negative switches S 3 , S 6 , S 9 , S 12 , S 15 , S 18 , S 21 , S 24 , S 27  are open. Switches S 2 , S 5 , S 8 , S 11 , S 14 , S 17  and S 20  are open and switches S 4 , S 7 , S 10 , S 13 , S 16 , S 19  and S 22  are closed. Switch  23  is now opened and switch  24  is now closed, connecting batteries V 1 , V 2 , V 3 , V 4 , V 5 , V 6 , V 7  and V 8  in series with the SSC output.  
         [0100]     The SSC  650  now switches back to CHARGE mode and charges the PFN from 8200 to 9200 volts by the series voltage addition of SSC Vout and V 1 , V 2 , V 3 , V 4 , V 5 , V 6 , V 7 , V 8  (8 kV).  
         [0101]     Vout varies over a range from 0-1200 volts. At PFN Charge voltage of 9200 Volts, the SSC goes back into IDLE mode for the Step 10 ERB configuration change.  
         [0102]     Step 10—Erecting Ninth battery stage PFN voltage 9200-10200 volts: SSC  650  starts step 10 cycle in IDLE mode, Vout and Iout are at zero, negative switches S 3 , S 6 , S 9 , S 12 , S 15 , S 18 , S 21 , S 24 , S 27  are open. Switches S 2 , S 5 , S 8 , S 11 , S 14 , S 17 , S 20  and S 23  are open and switches S 4 , S 7 , S 10 , S 13 , S 16 , S 19 , S 22  and S 25  are closed. Switch  26  is now opened and switch  28  is now closed, connecting batteries V 1 , V 2 , V 3 , V 4 , V 5 , V 6 , V 7 , V 8  and V 9  in series with the SSC output.  
         [0103]     The SSC  650  now switches back to CHARGE mode and charges the PFN from 9200 to 10200 volts by the series voltage addition of SSC Vout and V 1 , V 2 , V 3 , V 4 , V 5 , V 6 , V 7 , V 8 , V 9  (9 kV). Vout varies over a range from 0-1200 volts. At PFN full charge voltage of 10200 Volts, the SSC current drops to zero and then acts as a voltage regulator maintaining the charge in the PFN at the proper voltage.  
         [0104]     Step 11—De-Erecting:  
         [0105]     Just prior to firing the PFN capacitor bank  680 , the SSC  650  is shut off and all the switches are opened. In the event of a short, the HV contactor S 1  is opened and the SSC  650  is shut off and all of the switches are opened.  
         [0106]      FIG. 7  depicts an alternative embodiment of the invention  700 . In this embodiment, the system consists of several ERB arms  701 ,  702 ,  703 , and  704 , configured in a “star” configuration  712 . The redundancy of this configuration has several advantages including fault tolerance. Switch steering matrices are connected to both the inner  713  and outer portions of the star configurations. The ERB arms are connected at one end to the parallel low voltage or baseline voltage  705  and at the other end to the variable high voltage load  706 . Each of the two ends of an ERB arm (e.g.  701 ) has a bi-directional power output connection. The energy from the base side connection  713  of each arm (e.g.  701 ) is fed in parallel to the center switch matrix to provide traction power for the main system load. The outer switch matrix consists of positive diode switch matrix  710 , negative diode matrix  711  and switch  708  and switch  714  located below the capacitor below storage capacitor  707 .  
         [0107]     Diode switches  710  and  711  are voltage controlled switches that are turned on when the differential voltage between the arm output and the capacitor terminal forward bias the voltage across the diodes. The diode disconnect when the voltage differential between the capacitor and the individual arm output results in reverse biasing if one arm or both arms output voltage are below the capacitor voltage the one or both arms are disconnected by the diodes.  
         [0108]     Normal operation is when the modules are de-erected and disconnected causing diode switch matrices  710 , 711  to be back biased resulting in turning off the switches, then switch  708  and the other switch by base are then turned on to connect the energy stored in capacitor  707  to be transferred to the load.  
         [0109]     The energy stored in each arm can also be directed out the opposite end  710  to be directed through the VHV connection into the outer switch matrix  708 . Additionally the energy flow is in discrete energy packets that are time multiplexed on the VHV connection side while maintaining a continuous connection and energy flow through the base or parallel connection side  713 . Additionally, energy from one ERB arm (e.g.  701 ) can be transferred to another ERB arm (e.g.  702 ). A simple switching algorithm and a three-switch one diode configuration can be used to guarantee no catastrophic battery or file failure due to mistiming of the high-speed switching. This is accomplished by switching off or opening all of the positive or negative rail switches and then using just one series switch connection and one required steering diode per module to erect and de-erect the batteries or capacitors that are in series.  
         [0110]     Alternatively, the base switch matrix can be set to “ON” (i.e. the switch closed) at all times by replacing it with hard wired parallel connections of the base voltage terminals. The invention allows simple scaling by the simple addition of more modules without any rewiring. Sophisticated ERB systems with complete redundancy of the ERB star and multiple star configurations are easily configured by switched in and cross connected at the base and or at the VHV level matrix levels.  
         [0111]     In an alternative embodiment, for the purposes of redundancy and reliability, the VHV outputs are steered in parallel operation through a simple VHV diode steering array. This allows complete or partial failure of one or more ERB arms  701 ,  702 ,  703 , or  704  while maintaining function of the entire system. For instance the system  700  depicted in  FIG. 7  can suffer a complete failure of one plus (e.g.  701 ) and one minus output ERB arm (e.g.  702 ) and still meet most of the requirements of the VHV load. When used for powering an electric or gas-electric hybrid, the system can suffer the loss of three ERB arms before loosing traction or moving capability.  
         [0112]     As can be seen from  FIG. 8 , each of the ERB arms  801  is comprised of several ERB modules  802 . Each ERB module  802  contains an energy storage device  803 , such as a battery or capacitor, and piece of the distributed modular bus structure and steering array. It would be understood by one skilled in the art that any of the modular diagrams disclosed in  FIGS. 1-6  could be used to construct an ERB arm.  
         [0113]      FIG. 9  illustrates another embodiment of the invention. Each ERB arm  910  consists of a scalable number of ERB modules  920 . In such an embodiment each module  920  contains an energy source, part of the modular distributed series and parallel switch matrix and bus bar system, and the fusing and protection as well as the control systems. While the preferred embodiment has two input power ports  960  and two output power ports  950 , any number of power ports could be used. The ERB arms are scaled by connecting an output port  950  of a first module  920  to an input port  960  of a second module  930  to create a module string. This can be done for a plurality of ERB modules with the final module  970  in the string connecting to the VHV steering array  940 . Very high voltages can be achieved in this fashion. Because this application of the ERB modules is scalable, the number of modules per ERB arm is application driven and, in a multiple arm ERM “star” configuration system, each arm may have a different number of modules and have a different polarization of output voltage to satisfy a wide variety of load requirements.  
         [0114]     In examples shown in  FIGS. 7 and 8  and described above, 2 identical sets of one positive and one negative stackable module arms were chosen with the positive 5000 volt arms and HV outputs shown on the left and the negative 5000 volt arms and HV outputs shown on the right. One half of high voltage steer able diode switch matrix was added to each side so any number of arms can be added in parallel.  
         [0115]     The purpose of splitting the module chain or arms in half was to reduce the number of modules per arm connected to a common center parallel base core buss thus reducing the battery system ESR (Equivalent Series resistance) by a factor of 4 in the parallel mode and increase reliability by having 4 parallel arms vs. 2 arms. Also by splitting into positive and negative arms the differential voltage is double the voltage to reference to ground simplifying insulation systems  
         [0116]     Not shown are that multiple high voltage switch matrixes and loads can be shared among multiple stars. The Low Voltage parallel arm end (base in  FIG. 7 ) are connected to a common star low voltage buss or battery system and outer end or HV end of each arm can be connected to a single, or multiple outer switch high voltage switch matrixes,  
         [0117]     An 8 arm star (star-1) can be implemented by adding four more arms to the H configuration with 8 arms of stackable modules with 4 arms connected to HV matrix—one connected to pulsed laser system, arms  5 - 6  connected to HV Switch matrix—2 and Pulsed Microwave system, arms  7 - 8  connected HV traction system.  
         [0118]     Thus, additional stars can add their arms outputs and be cross-connected at both the inner outer hubs or arm ends to the Star-1 for redundancy or more power.  
         [0119]     Thus, a number of preferred embodiments have been fully described above with reference to the drawing Figs. Although the invention has been described based upon these preferred embodiments, it would be apparent to those of skill in the art that certain modifications, variations, and alternative constructions could be made to the described embodiments within the spirit and scope of the invention. Further, as should be apparent to one skilled in the art after reviewing this patent document, the modular battery system of the present invention could be useful in innumerable other applications not listed here.

Technology Category: 7