CN105209287A - Electric energy storage and power management system - Google Patents

Abstract

An electrical energy storage system includes a plurality of electrical energy storage modules, each module having an associated operating voltage and each module capable of outputting power at a variable current at the associated operating voltage. The system also includes a plurality of power modulation circuits electrically connected to one of the modules, thereby allowing the associated module to be electrically isolated from other modules of the system. Each power modulation circuit includes a circuit for receiving a module operating voltage and current of the associated module, converting the operating voltage and current, and outputting power at a voltage independent of the module operating voltage of the associated electrical energy storage module. The system also includes an overall master controller electrically connected to each power modulation circuit of each module to control the power of each output of the module.

Description

Electric energy storage and power management system

related application

This application claims priority to US Provisional Application No. 61/786,003, filed March 14, 2013, which is hereby incorporated by reference in its entirety.

Background technique

The electric vehicle industry continues to seek electric drive systems and cost-effective electrical energy storage systems with increased efficiency and power density. It has long been believed that electric motors and/or generators, such as those constructed using stators and permanent ultra-strong magnet rotors such as cobalt rare earth magnets and neodymium iron boron magnets, include electromagnets with cores formed of thin-film soft magnetic materials. Electric motors have the potential to offer much higher efficiencies and power densities than conventional motors. However, providing electric drive systems and cost-effective electrical energy storage systems that fully exploit these potential efficiencies has proven difficult.

Variable speed motors used in electric vehicles are typically controlled by a controller using battery pack voltage from a battery pack, which typically consists of multiple electrically interconnected cells. The battery has an operating battery voltage that is generally based on the type of battery used, and the total battery voltage is generally determined by the battery construction. Battery voltage is typically increased by interconnecting individual groups of cells in series to achieve a desired battery voltage, and groups of cells connected in series are typically connected in parallel to increase the current carrying capacity of the overall battery.

Many electric vehicles now use lithium-ion battery packs because of their high power density and ability to be recharged repeatedly. To provide the performance characteristics required for this type of application, these lithium-ion battery packs are typically designed to operate at higher voltages and higher currents. The use of high voltages can create significant safety concerns, and there may be significant reliability issues associated with battery packs that include a large number of battery banks connected in parallel. However, many high performance electric motors have an optimum voltage operating point that may be higher than that generally available for Li-ion battery systems, since the size and voltage of the Li-ion battery pack may be limited due to safety concerns.

Contents of the invention

In some aspects, the present disclosure provides power management systems and methods for electrical energy storage systems. The electrical energy storage system includes a plurality of electrical energy storage modules, wherein each electrical energy storage module has an associated electrical energy storage module operating voltage. Each electrical energy storage module is capable of outputting power at a different current related to the operating voltage. The electrical energy storage system includes a plurality of power modulation circuits, wherein each power modulation circuit is electrically connected to an associated one of the electrical energy storage modules, thereby allowing the associated coarse electrical energy storage module to electrically communicate with other electrical energy storage modules of the electrical energy storage system. isolation. Each power modulation circuit includes arrangements for receiving an operating voltage and current of an associated electrical energy storage module, converting the operating voltage and current, and outputting electrical power at a voltage independent of the operating voltage of the associated electrical energy storage module. The electrical energy storage system also includes an overall master controller electrically connected to each power modulation circuit of each electrical energy storage module to control the power output by each electrical energy storage module and thereby control the electrical output of the overall electrical energy storage system. In some aspects, each battery storage module includes a plurality of individual batteries, where each battery has an associated battery operating voltage.

In some aspects, the individual batteries are lithium-ion batteries.

In some aspects, the batteries that make up the different electrical energy storage modules of the energy storage system have different energy storage characteristics.

In some aspects, the cells that make up the different electrical energy storage modules of the energy storage system have different lithium ion chemistries and different energy storage densities.

In some aspects, the multiple batteries making up each electrical energy storage module are all connected in series.

In some aspects, each power modulation circuit includes a buck/boost converter for converting an operating voltage associated with the electrical energy storage module to a voltage that is independent of and can be higher than the operating voltage associated with the electrical energy storage module.

In some aspects, different electrical energy storage modules of the electrical energy storage system have different characteristics selected from a group of characteristics including different operating voltages and different energy, inductance, and current capacities.

In some aspects, the overall master controller is a motor controller and the electrical energy storage system is an electrical energy storage system for an electric motor including a rotor having a plurality of rotor poles.

In some aspects, the electric motor is a brushless DC motor/generator.

In some aspects, the overall master controller includes multiple independent controllers. Each individual controller is electrically connected to the associated power modulation circuit to independently control the associated power modulation circuit and the associated electrical energy storage module. Independent power modulation circuits cooperate to produce a single drive function that drives the electric motor.

In some aspects, the overall master controller includes a plurality of individual controllers, wherein each individual controller is electrically connected to an associated power modulation circuit to independently control the associated power modulation circuit and the associated electrical energy storage module. The electric motor includes a stator having a plurality of individual stator modules, where each individual stator module includes a plurality of stator poles that magnetically interact with rotor poles. Each stator module is electrically connected to an associated independent controller and thereby to an associated power modulation circuit and electrical energy storage module to form a plurality of electrically independent sub-motors each capable of operating independently of the other sub-motors .

In some aspects, each stator module includes a set of coils that charge the stator poles. The set of coils has one or more coil subgroups, wherein each coil subgroup is associated with a different magnetic phase of the stator module and all coils making up each serially electrically connected coil subgroup.

In some aspects, the electric motor provides electrical power to the vehicle.

In some aspects, the electric motors are direct drive wheel motors.

In some aspects, an overall master controller applies a variable drive voltage to the motor.

In some aspects, an overall master controller applies a variable drive voltage to the motor.

In some aspects, the motor is a multi-phase motor and the overall master controller applies a variable drive voltage and current function to each phase of the motor by pulse width modulating the drive voltage applied across the phases and varying the voltage applied to the drive voltage.

In some aspects, the overall master controller varies drive voltage and current functions in ways that vary motor speed, requested motor power output and efficiency, response, life, smoothness, and optimization of maximum available power.

In some aspects, the overall master controller increases the drive voltage using a predetermined function as the speed of the motor increases and as the requested motor power output increases.

In some aspects, the overall master controller controls the amount of electrical energy provided to the motor by switching the drive voltage applied to the motor using pulse width modulation. The overall master controller also varies the switching speed of the pulse width modulation in a manner that varies one or more of the requested motor power output and the speed of the motor.

In some aspects, the master master controller varies the switching speed and drive voltage of the pulse width modulation applied to the motor to optimize the efficiency of the motor, the power of the motor, the heat of the motor, the noise of the motor, the speed and torque of the motor and the electrical energy storage system One or more of the lifetimes.

In some aspects, the power modulation circuitry and the overall master controller of each electrical energy storage module allow electrical energy to be released from a given electrical energy storage module only when the overall master controller requests electrical energy to be released from the given electrical energy storage module.

In some aspects, each power modulation circuit includes at least one pair of power terminals through which electrical energy is discharged from the associated electrical energy storage module. The power terminals are controlled by power modulation circuitry associated with the power storage modules to activate the power terminals and allow release of electrical energy from the electrical energy storage modules only when the overall master controller requests electrical energy to be released from the electrical energy storage modules.

In some aspects, the overall master controller includes multiple independent controllers. Each individual controller is electrically connected to the associated power modulation circuit to independently control the associated power modulation circuit and the associated electrical energy storage module. The electrical energy storage system includes at least one auxiliary electrical energy storage module having an associated auxiliary electrical energy storage module operating voltage and an auxiliary power modulation circuit electrically isolating the auxiliary electrical energy storage module from other electrical energy storage modules of the electrical energy storage system. The auxiliary power modulation circuit includes receiving the operating voltage of the auxiliary power storage module and the current of the auxiliary power output module, converting the operating voltage and current, and outputting a voltage and current independent of the operating voltage of the auxiliary power storage module. The auxiliary electrical energy storage modules are electrically connected to and controlled by an independent controller associated with a given one of the electrical energy storage modules.

In some aspects, each electrical energy storage module includes a module housing for housing the electrical energy storage module and associated power modulation circuitry. The module housing includes a protruding length of thermally conductive material and an end cap for sealing an end of the protruding length of material.

In some aspects, the end cap provides a watertight seal and the protruding material is protruding aluminum having a cross-sectional shape including a heat dissipation surface and at least one heat dissipation flange configured to attach to the heat dissipation support.

In some aspects, the present disclosure provides motor controllers and methods for controlling a variable motor powered by a power source having an electrical operating voltage. The controller includes a voltage varying arrangement that receives an electrical operating voltage from the power supply, transforms the operating voltage and outputs a variable drive voltage that is applied to the motor and is independent of the power supply operating voltage. The controller also includes a switching arrangement that switches by pulse width modulation and applies a variable voltage to the motor to control the amount of electrical energy provided to the motor. The controller varies the switching speed of the pulse width modulation and varies the variable drive voltage in a manner that varies one or more of the requested motor power output and the motor speed.

In some aspects, the controller varies the switching speed of the pulse width modulation and varies the variable drive voltage applied to the motor to optimize the efficiency of the motor, the power of the motor, the heat of the motor, the noise of the motor, the speed and torque of the motor, and the One or more of lifetimes.

In some aspects, the controller varies the switching speed of the pulse width modulation and varies the variable drive voltage applied to the motor by using a predetermined function as the speed of the motor changes and the requested motor power output changes.

In some aspects, the power source includes at least one lithium-ion battery.

In some aspects, the present disclosure includes battery modules for use in electrical energy storage systems. The battery module includes at least one battery and a module housing for receiving the battery. The module housing includes a protruding length of thermally conductive material and end caps for sealing the ends of the protruding length of material.

In some aspects, the end cap provides a tight seam and the protruding material is protruding aluminum having a cross-sectional shape that includes a heat dissipation surface and at least one heat dissipation flange configured to attach to the heat dissipation support.

In some aspects, the battery is a lithium ion battery.

In some aspects, the cells are all connected in series.

In some aspects, the cells are electrically interconnected to provide a battery pack voltage and the battery pack further includes a power modulation circuit configured to be controlled by an external controller such that the battery pack voltage cannot enter from the outside of the battery pack unless commanded by the external controller .

In some aspects, a battery module is configured for use in an electrical energy storage system having a plurality of battery modules and the power modulation circuit is configured to allow the battery modules to fail and be electrically isolated from the system.

In some aspects, a battery module includes a plurality of parallel-connected battery groups, each parallel-connected group including at least one battery, and the parallel-connected battery groups are electrically connected in series to another group.

In some aspects, the battery module includes a cell balancing arrangement electrically connected to each of the parallel-connected battery groups such that energy harvested from the battery module can be obtained from a subset of the parallel-connected battery groups.

In some aspects, the battery balancing arrangement derives energy from the parallel-connected battery packs such that the battery module receives power from a subset of the parallel-connected battery packs to an electrical device or other external electrical device electrically connected to the battery module during use of the battery module. The load provides energy, thereby providing a cell balancing function for the battery module during use of the battery module.

Description of drawings

FIG. 1 is a schematic illustration of a power management system for an electric drive system and an energy storage system according to the present disclosure.

FIG. 2 is a schematic illustration of an electric drive system according to the present disclosure.

FIG. 3 is a cross-sectional view of the motor of FIG. 2 .

FIG. 4 is a perspective view of a stator section of the electric machine of FIG. 2 .

FIG. 5 is a plan view of a stator core used to provide the stator section of FIG. 4 .

FIG. 6 is a plan view of two stator cores of the stator section of FIG. 4 .

FIG. 7 is a schematic illustration of another strength of an electric drive system according to the present disclosure.

Figure 8 is a schematic illustration of an auxiliary electrical energy storage module and an electrical energy storage module associated with teachings in accordance with the present disclosure.

9 is a cross-sectional view of a module housing of the electrical energy storage module of FIG. 8 .

FIG. 10 is a flowchart illustrating steps of a method of controlling the same according to the present disclosure.

11 is a graph of a single magnetic cycle for a single phase of an exemplary electric machine according to the present disclosure, with the y-axis representing voltage and the x-axis representing time.

Like reference numerals denote like elements in the drawings.

Detailed ways

The present disclosure generally relates to electrical energy storage systems, electric drive systems, controllers, and power management systems. The present disclosure also relates to arrangements and methods of controlling larger battery systems, such as battery packs used in electric vehicles. The present disclosure also includes arrangements and methods for electrically interconnecting and controlling components of electric drive systems and electric energy storage systems including electric machines such as electric motors and/or generators powered by the electric energy storage system.

Referring to FIG. 1 , a general overall power management system 100 for an electrical energy storage system 102 in accordance with the present disclosure will be described. The electrical energy storage system 102 includes a plurality of electrical energy storage modules 104, wherein each electrical energy storage module 104 has an associated electrical energy storage module operating voltage V1. In the embodiment illustrated in FIG. 1 , the electrical energy storage system 102 includes six electrical energy storage modules 104 , which are denoted by reference numerals V1a to V1f, respectively. Although electrical energy storage system 102 is described as having six modules, this is not a requirement. Alternatively, the electrical energy storage system may comprise any desired number of modules.

The electrical energy storage system 102 also includes a plurality of power modulation circuits 106 . In the illustrated embodiment of FIG. 1 , the electrical energy storage system 102 includes six power modulation circuits 106 , which are indicated by reference numerals 106a to 106f. Each power modulation circuit 106a - f is electrically connected to an associated one of the electrical energy storage modules 104a - f to allow each associated electrical energy storage module 104 to be electrically isolated from the other electrical energy storage modules of the electrical energy storage system 102 . In accordance with the present disclosure, the power modulation circuits 106a-f may be incorporated as part of the electrical energy storage modules 104a-f illustrated in FIG. 1 . As will be described in detail below, this can provide significant safety advantages to the energy storage system. Alternatively, the power modulation circuit may be provided as discrete components which may be electrically connected to the electrical energy storage module rather than being included as an integral part of the module.

As will be described in detail below, each power modulation circuit 106a-f includes a respective output arrangement 108a-f for receiving an electrical energy storage module operating voltage V1a-f and current from an associated electrical energy storage module, converting said operating Voltage and current and output voltage V2 and current independent of the operating voltage V1a-f of the electrical energy storage module. The electrical energy storage system 102 also includes an overall master controller 110 electrically connected to each of the power modulation circuits 106a-f. In this embodiment, pairs of electrical conductors 111 (represented by the figure and 111a through 111f) are used to transfer power between the controller 110 and the power modulation circuits 106a-f, respectively. The controller 110 is configured to control the operation of the power modulation circuit 106 by using a communication bus 112 interconnecting the controller 110 and the power modulation circuits 106a-f. Communication bus 112 may be any desired type of communication bus, such as, but not limited to, a CAN bus. With this configuration, the controller 110 can control the electrical output from each electrical energy storage module, and thereby control the electrical output of the overall electrical energy storage system 102 . The communication bus 112 may also be used to communicate the status of each of the electrical energy storage modules that are part of the energy storage management system.

According to some aspects of the present disclosure, each electrical energy storage module 104 may include one or more electrical energy storage components 113 for storing electrical energy. In a preferred embodiment, the electrical energy storage unit 113 may be a Li-ion battery having the desired Li-ion battery chemistry and battery voltage V3. While the various embodiments described herein will be described as using a lithium-ion battery as the electrical energy storage component for storing electrical energy in the energy storage module, it should be understood that this is not a requirement. Alternatively, any electrical energy storage component may be used, including other types of batteries, various types of capacitors such as ultracapacitors, an electrical energy storage flywheel, or any other electrical energy storage component.

According to another aspect of the present disclosure, different electrical energy storage modules 104 included in the electrical energy storage system 102 may have different electrical energy storage module characteristics, such as different module operating voltages V1 . For example, where the electrical energy storage modules comprise batteries as the electrical energy storage component 113, the batteries of one electrical energy storage module may have different energy storage characteristics compared to another electrical energy storage module. These features could be different lithium ion chemistries and/or different energy storage densities. Furthermore, the cells that make up each electrical energy storage module can be interconnected in different ways. For example, all cells of an electrical energy storage module can be connected in series. Alternatively, the batteries making up another electrical energy storage module may be connected in any combination of parallel and series to provide the desired module operating voltage V1 and ampacity of the electrical energy storage module. Where different electrical energy storage modules of the system have different module operating voltages, each output arrangement 108 may be used to convert the different module operating voltages of the different modules to the same output voltage V2.

The overall master controller 110 and the power modulation circuits 106a-f of each of the electrical energy storage modules 104a-f may be configured to allow power to flow from a given electrical energy storage module only when the overall master controller 110 requests that current be released from the electrical energy storage module 104. 104 released. For example, each electrical energy storage module 104a-f may include a pair of power terminals 114 through which electrical energy is discharged from the associated electrical energy storage module 104 . The power terminal 114 may be controlled by the power modulation circuit 106 to activate the power terminal 14 and allow the release of electrical energy from the electrical energy storage module only when the overall master controller 110 requests electrical energy to be released from the electrical energy storage module.

Each electrical energy storage module 104a-f may also include a charger 115, indicated by reference numerals 115a to 115f, for charging the electrical energy storage components of the electrical energy storage module. The chargers 115a-f may be controlled by a controller 110, which may communicate with the chargers 115a-f using the communication bus 112 and control the operation of the chargers 115a-f. Controller 110 may include an external power input 116 for receiving power from an external source for charging electrical energy storage system 102 using chargers 115a-f. While chargers 115a-f are described as being included within their respective electrical energy storage modules, it should be understood that this is not a requirement. Alternatively, the charger may be provided in a variety of locations including, but not limited to, being included in the controller 110 or provided as a separate component electrically connected to the controller 110 and the energy storage modules 104a-f.

In a preferred embodiment, each of the output arrangements 108a-f of the power modulation circuits 106a-f may comprise a buck/boost converter 117 , indicated by reference numerals 117a to 117f , which is controlled by the controller 110 . Likewise, controller 110 may communicate with and control the operation of buck/boost converters 117a - f using communication bus 112 . The buck/boost converters 117a-f are electrically connectable to their respective electrical energy storage components 113 to receive their respective electrical energy storage module operating voltages V1a-f and convert the module operating voltages to an output voltage V2 which is independently at and can be higher or lower than the module operating voltage V1a-f.

As illustrated in FIG. 1 , the power management system 100 and the electrical energy storage system 102 may be a system for an electric machine 118 . Electric machine 118 may include, but is not limited to, an electric motor and/or generator having a rotor assembly 120 and a stator assembly 122 . Controller 110 may be a motor controller that regulates operation of motor 118 based on input signal 124 and position signal 126 . The input signal 124 may include a requested motor torque or power output, a throttle signal in the case of the motor 118 operating in a vehicle, motorcycle, scooter, or the like. The motor 118 may also include a Hall effect sensor or other position sensing arrangement 128 for detecting the position of the rotor assembly 120 relative to the stator assembly 122 . The Hall effect sensor or other position sensing arrangement 128 may generate a position signal 126 that is used by the controller 110 . When the electric machine 118 is operating in the motor mode, the controller 110 may regulate the power provided to the electric machine 118 from the electrical energy storage system 102 . Additionally, when electric machine 118 is operating in generator mode, electric machine 118 may generate electrical power that may be provided to and stored in electrical energy storage system 102 .

Although the position detection arrangement is described as a Hall effect sensor, it should be understood that this is not a requirement. Alternatively, any available and readily available position detection arrangement may be used. For example, where a high frequency motor is used, a capacitive encoder may be used.

Although the motor 118 is described herein primarily as being provided as a DC brushless motor, the motor 118 may be provided as one of a number of other types of motors and remain within the scope of the present disclosure. This includes, but is not limited to, DC synchronous motors, variable reluctance or switched reluctance motors, and induction motors. For example, where the motor 118 is provided as a DC brushless motor, the rotor poles of the motor 118 may be provided as permanent magnets. In the case of switched reluctance motors or induction motors, the rotor poles may be provided as protrusions of other magnetic material formed from laminations of iron or preferably thin-film soft magnetic material. In other arrangements, the rotor poles may be provided as electromagnets.

According to another aspect of the present disclosure, the controller 110 may apply variable driving voltage V4 and current to the motor 118 . As will be described in detail below, the controller 110 may vary the drive voltage V4 and current in a manner that varies according to the speed of the motor and/or the requested motor torque or power output as part of the input signal 122 . The controller 110 may use a predetermined function to increase the drive voltage V4 as the speed of the motor 18 increases and as the requested motor torque or power output increases. The controller 110 may also vary the drive voltage and current to optimize one or more of the efficiency of the motor, power of the motor, heating of the motor, noise of the motor, speed and torque of the motor, life of the electrical energy storage system, or any other function of the system. indivual.

The controller 110 may also include a switching arrangement 130 for controlling the amount of electrical energy provided to the motor 118 by switching the current applied to the motor 118 and the drive voltage V4 using pulse width modulation. According to another aspect of the present disclosure, the controller 110 may vary the switching speed of the switching arrangement 130 to vary the switching speed of the pulse width modulation applied to the motor 118 . The controller 110 may also vary the switching speed and drive voltage of the pulse width modulation used to drive the motor 118 . This approach can be used to optimize one or more of the efficiency of the motor, the power of the motor, the heating of the motor, the noise of the motor, the speed and torque of the motor, the life of the electrical energy storage system, or any other function of the system.

In a preferred embodiment, the controller 110 controls the buck/boost converters 117a-f in each of the power modulation circuits 106a-f of each electrical energy storage module 104a-f such that each module operates at the desired The electric energy is output under the output voltage V2. The output voltage V2 is selected to be equal to the desired drive voltage V4. The controller 110 may use pulse width modulation to control the amount of electrical power provided to the motor 118 and the controller may select a desired switching speed for the pulse width modulation. Both the switching speed of the pulse width modulation and the drive voltage can be varied to optimize the operation of the motor. To achieve this, and as will be described in detail below, the motor and overall system can be fully characterized or tested to determine the optimum drive voltage and switching speed for the pulse width modulation for the entire operating range of the system. The results of this test can be compiled into a lookup table or run function. These tables or functions can be included in the system and made available to the controller 110 so that the controller 110 can select and use the desired pulse width modulated drive voltage and switching speed for any given situation throughout the operating range of the system .

Motor 118 may be a three-phase motor and controller 110 may use three electrical conductors 132 to provide drive voltage V4 to motor 118 . Although motor 118 is described herein as a three-phase motor, this is not a requirement. Alternatively, the motor may utilize any desired number of phases and still be within the scope of the present disclosure. As will be understood by those skilled in the art, the number of electrical conductors 132 used to electrically connect the controller to the motor and provide the drive voltage to the motor depends on the number of phases used in the motor according to the configuration described above.

Although the controller is shown in FIG. 1 as a single overall controller, it should be understood that this is not a requirement. Alternatively, the controller may be provided in various ways. For example, the general controller may include a plurality of independent self-controlling authorities, each independent controller being electrically connected to an associated power modulation circuit to independently control the associated power modulation circuit and the associated energy storage module.

Now, a general general power management system designed according to the teachings of the present invention has been described with reference to FIG. 1 . A specific preferred embodiment of an electric drive system 200 according to the present disclosure will be described below with reference to FIGS. 1 and 2 . In this embodiment, system 200 is an electric drive system for a variable speed motor/generator for powering an electric vehicle.

As described above with respect to the power management system 100, the system 200 includes an electrical energy storage system 102 having six electrical energy storage modules 104, indicated by reference numerals 104a through 104f. Each electrical energy storage module 104 has an associated electrical energy storage module operating voltage V1, the subdivisions of which are indicated by reference numerals V1a to V1f. As noted above, while electrical energy storage system 102 is described as including six modules, this is not a requirement. Alternatively, the electrical energy storage system may include any number of modules.

Each of the electrical energy storage modules 104a-f of the system 200 also includes an associated power modulation circuit 106, indicated by reference numerals 106a to 106f, respectively. As described above, power modulation circuits 106 a - f can be used to electrically isolate each associated electrical energy storage module 104 from other electrical energy storage modules of electrical energy storage system 102 . Each of the power modulation circuits 106a-f further comprises an output arrangement 108, indicated by reference numerals 108a to 108f respectively, for receiving the energy storage module operating voltage V1a-f of its associated energy storage module, converting said operating voltage and output output voltages V2a-f independent of the operating voltages V1a-f of the electric energy storage modules. In this embodiment, the output arrangements 108a-f of the power modulation circuits 106a-f comprise buck/boost converters 117a-f, respectively. Each of the electrical energy storage modules 104a-f of the system 200 may also include an associated charger 115, indicated by reference numerals 115a to 115f, respectively.

Each electrical energy storage module 104 of the system 200 also includes a plurality of individual electrical energy storage components 113 for storing electrical energy. In this particular example, each electrical energy storage module 104 includes 78 individual lithium-ion cells having nickel cobalt manganese oxide cathodes, graphite anodes, and a cell voltage V3 of approximately 3.7 watts. The 78 cells are electrically interconnected with 13 groups of six parallel-connected cells to form 13 parallel-connected cell groups. The 13 parallel battery groups each have a nominal operating voltage of approximately 3.7 watts and they are connected in series to provide a nominal module operating voltage V1 of approximately 48 watts. As noted above, while this embodiment is described as using lithium-ion cells interconnected to provide a module operating voltage of 48 watts, it should be understood that this is not a requirement. Alternatively, any desired electrical energy storage components may be used and these components may be interconnected in any desired manner to provide any desired module operating voltage. For example, the same 78 cells as described above could all be connected in series to provide a module with a module operating voltage of approximately 288 watts. Furthermore, while all of the electrical energy storage modules of this particular embodiment are described as having the same configuration and module operating voltage, this is not a requirement. Alternatively, each electrical energy storage module may have a different configuration and module operating voltage than the other electrical energy storage modules of the system.

Although each power module is described as including a single power modulation circuit 106, it should be understood that each module may include multiple power modulation circuits. For example, the 78 cells described above can be electrically interconnected with 13 groups of 6 cells connected in parallel. Each of the 13 parallel connected groups of 6 cells may have its own power modulation circuit to allow each parallel connected group to be electrically isolated from other parallel connected groups of modules. All 13 parallel connected battery banks associated can be connected in series to provide a nominal module operating voltage V1 of approximately 48 watts.

As described above with respect to system 100, system 200 also includes an overall master controller 110 electrically connected to each of power modulation circuits 106a-f to control the operation of power modulation circuits 106a-f. However, in system 200, controller 110 includes six sub-controllers 110a through 110f that are each included within or as an integral part of electrical energy storage modules 104a through 104f. The main controller 110 controls and coordinates the operation of the sub-controllers 110a-f and each of the sub-controllers 110a-f is configured to control their respective power modulation circuits 106a-f and buck/boost converters 117a-f to Each electrical energy storage module is made to output a desired electrical output at a desired output voltage V2a-f. As will be described in detail below, these output voltages V2a-f may all have the same voltage, or alternatively, the output voltages may have different voltages.

System 200 also includes motor 202 . In this embodiment, the electric machine 202 is provided as a radial gap electric machine having a rotor assembly 204 and a stator assembly 206 located at the periphery of the electric machine 202 . Motor 202 is a brushless DC motor/generator with rotor assembly 204 having a plurality of permanent magnet rotor poles placed around the inner circumference of rotor assembly 204 and is a direct drive wheel motor that provides electrical power to the vehicle.

As described above with respect to system 100 , controller 110 regulates operation of motor 202 based on input signal 124 and position signal 126 . In this embodiment, the input signal 124 includes a requested motor torque and a power output such as a throttle signal. The electric machine 202 also includes a Hall effect sensor or other position sensing arrangement 128 for detecting the position of the rotor assembly 204 relative to the stator assembly 206 . The Hall effect sensor or other position sensing arrangement 128 generates a position signal 126 used by the controller 110 .

In the arrangement of FIG. 2 , the rotor assembly 204 is placed around the periphery of the electric machine 202 . That is, the stator assembly 206 is surrounded by the rotor assembly 204 . Although not illustrated in FIG. 2 , rotor assembly 204 may be supported by bearings for rotation relative to stator assembly 206 . Radial gap 208 separates rotor assembly 204 from stator assembly 206 . In alternative arrangements, rotor assembly 204 may be supported for rotation about axis of rotation 210 relative to stator assembly 206 by other suitable means. Although the electric machine 202 is described as a radially spaced electric machine having a stator assembly surrounded by a rotor assembly, this is not a requirement. Alternatively, the electric machine may be a radially spaced electric machine having a stator assembly surrounding a rotor assembly. Alternatively, the rotor assembly and the stator assembly may be axially adjacent to each other to form an axially spaced electric machine.

In the embodiment of FIG. 2 , rotor assembly 204 includes 56 pairs of radially adjacent permanent magnets 212 that form rotor poles of rotor assembly 204 . In some implementations, the pair of permanent magnets 212 may be provided as supermagnets such as cobalt rare earth magnets or any other suitable or readily available magnet material. As best illustrated in the cross-sectional view of Figure 3, each of the permanent magnet pairs 212 includes a first magnet oriented to form a north rotor pole 212a, a second magnet oriented to form a south rotor pole 212b. The first magnet is positioned adjacent to the second magnet such that the two permanent magnets are in-line with each other along an axis of rotation 210 that is generally parallel to the motor 202 . Thus, as the rotor assembly 204 rotates, the two permanent magnets define adjacent circular paths about the axis of rotation 210 of the electric machine 202 . As shown in FIG. 3 , the permanent magnet pairs are positioned about the inner periphery of the rotor assembly 204 facing the radial spacing 208 . Each successive permanent magnet pair 212 is reversed such that all adjacent magnet segments alternate from north to south around the entire rotor assembly 204 .

Although the permanent magnet pairs 212 may be provided as permanent supermagnets, other magnet materials can also be used. In some embodiments, electromagnets may be used with rotor assembly 204 instead of permanent magnets. Furthermore, while the rotor assembly 204 of FIG. 2 is illustrated as including 56 magnet pairs, it is contemplated that the rotor assembly 204 may include any number of magnet pairs.

The stator assembly 206 includes a plurality of stator modules 214 . In the arrangement of FIG. 2 , the stator assembly 206 includes six stator modules 214 , which are indicated by reference numerals 214 a through 214 f in FIG. 2 for descriptive purposes. Although the stator assembly 206 is described as including six stator modules 214 , other arrangements are contemplated. For example, stator assemblies including more than six stator modules 214 or fewer than six stator modules 214 are within the scope of the present disclosure.

Each stator module 214 of electric machine 202 is independent of other stator modules 214 in stator assembly 206 . More specifically, each stator module 214 can be independently removed and replaced. In some implementations, the stator module 214 can be removed and the electric machine 202 can operate without the stator module 214 in its entirety. For example, referring to the specific arrangement of FIG. 2 , the electric machine 202 may operate with more or fewer than six stator modules 214 . That is, the electric machine 202 of FIG. 2 may operate with one, two, three, four, five, six, or seven stator modules 214 . Furthermore, the stator modules used can be arranged symmetrically or asymmetrically. For example, if two stator modules are used, stator modules 214a and 214b may be used to form an asymmetric version of electric machine 202 . Alternatively, modules 214a and 214d may be used to form a symmetrical version of motor 202 .

In electric machine 202 , each stator module 214 includes a stator module housing 216 and at least one stator segment 218 housed within stator module housing 216 . Preferably, each stator segment 218 is identical to all other stator segments of the electric machine 202 . In the arrangement of FIG. 2 , the electric machine 202 is provided as a three-phase electric machine, each stator module 214 comprising six stator segments 218 , which are indicated by reference numerals 218a to 218f respectively.

As best illustrated in FIG. 4 , each stator segment 218 includes a magnetic core 220 and two separate coils 222 . Each core 220 is a U-shaped core and one coil 222 is positioned around each leg of the core 220 . Because the magnetic core 220 includes legs with a constant cross-section, the electromagnetic coil or coil 22 can be slid over each leg of the magnetic core 220 after the coil 222 has been formed or wound. This allows each individual coil 222 to be wound economically on a high capacity and very simple winding machine. This ability to individually wind the coil 222 before being installed on the magnetic core 220 eliminates the need to use an expensive and complex winding machine to achieve the complicated winding process typically used to manufacture conventional motor.

In this example, round copper wire with a dielectric coating may be used to form coil 222 . However, it should be understood that any desired electrical conductor material and configuration may be used. This includes wires formed from other conductive materials than copper, such as aluminum. This also includes wires having any desired cross-sectional shape, such as profiled wire or sheet.

As illustrated in Figure 4, the individual coils 222 include two electrical leads 224 for electrically interconnecting each coil with the other coils of the motor. With this configuration, the electrical leads 224 of the coils 222 can be interconnected in a variety of different desired ways based on the particular needs of the motor. For example, in a three-phase machine, for a total of 12 coils 222, a 6 stator segment stator module would include 6 pairs of coils, with two of these coil pairs or two stator segments associated with each. In lower power versions of this type of motor, each group of two pairs of coils associated with each is interconnected in parallel. In higher power versions of this type of motor, each group of two pairs of coils associated with each is electrically interconnected in series. In a more modest power version of this type of motor, each group of two pairs of coils associated with each can be electrically interconnected so that there are two parallel groups of two series connected coils. Thus, multiple different stator module and motor configurations can be obtained by simply interconnecting the electrical leads 224 of the coils 222 using different configurations without changing any other components within the stator module. This provides the advantage of being able to use many of the same components to build a variety of motor configurations.

In this embodiment, each stator segment 218 may also include a core ring 226 attached to the sides of the U-shaped core at the ends of each leg of the U-shaped core. The core ring 226 may be configured to completely surround the ends of the U-shaped core 220 to provide enlarged stator pole faces 228 at each end of the core 220 . The use of the core ring 226 also allows the ends of the core 220 to extend through the core ring 226 so that the ends of the core 220 constitute at least part of the stator pole face 228 . Magnetic core ring 226 may also be formed from thin film soft magnetic material, powdered metal, or any other desired magnetic material. In a preferred embodiment, the magnetic core ring is formed from magnetically permeable metal powder pressed into the desired shape. As best illustrated in FIG. 4 , the core ring 226 may have a uniform thickness in a direction perpendicular to the stator pole face 228 . Using a consistent thickness allows the core ring 226 to be easily and economically pressed from powdered metal material.

Referring now to FIGS. 5 and 6 , the specific configuration of the exemplary magnetic core 220 for the particular embodiment of the electric machine 202 shown in FIG. 2 will be described in more detail. In this embodiment, each individual one-piece magnetic core 220 is formed by winding a continuous strip of thin film soft magnetic material into a desired shape. In this example, the shape is generally elliptical, as represented by winding 230 in FIG. 5 . These types of motors, which may include wound magnetic cores, are described in detail in US Patent Nos. 6,603,237, 6,879,080, 7,030,534, and 7,358,639, as well as in PCT Patent Applications PCT/US2010/048019, PCT/US2010/048027, and PCT/US2010/048028 , which documents are the applicant's and are hereby incorporated by reference.

Thin-film soft magnetic low-loss materials such as amorphous metals or nanocrystalline materials are typically used in thin continuous strips with a consistent bandwidth. Many other magnetic materials are also available in the form of long continuous strips. For the purposes of this description, the term tape wound core is intended to include any magnetic core that is formed by winding a thin strip of magnetic material in a coil.

Because thin film soft magnetic materials such as amorphous or nanocrystalline materials are typically provided in the form of very thin ribbons or ribbons (e.g., a few thousandths or thousandths of an inch or even less than a thousandth of an inch) , winding coil 230 may be composed of hundreds of layers or windings of material illustrated by line 232 in FIGS. 5 and 6 . Once wound into the desired shape, the wound coil 230 may be annealed to remove any stress that may have developed during the winding process. The coiled coil 230 is also impregnated with an adhesive material such as a very thin epoxy tin dip, which may be heat cured to bond the coiled coil 230 to a rigid part.

Once annealed, thin film soft magnetic materials can be very hard and very brittle, making them less easy to process. In the embodiment shown in FIGS. 5 and 6, the winding coil 230 requires only one cut to cut the winding coil 230 into two U-shaped pieces. Each U-shaped part may provide a magnetic core 220 . As illustrated in FIG. 6 , each of the two U-shaped parts produced by cutting and winding the coil 230 consists of a plurality of concentric U-shaped layers 234 of thin-film soft magnetic material.

In some implementations, the magnetic core 220 may be made of nanocrystalline, thin-film soft magnetic materials. In other implementations, any thin film soft magnetic material can be used and can include, but is not limited to, materials generally known as ferrosilicon, amorphous metals, similar in basic alloy composition, treated in some way to further reduce Small materials with crystal structures the size of amorphous metallic materials, as well as any other thin film materials. Although the thin film soft magnetic material making up the magnetic core 220 is mainly described as an amorphous metal or a nano-metal material, the present disclosure is not limited to these specific materials. Alternatively, any magnetic material that can be provided as a thin continuous strip or ribbon may be used to provide a tape wound core as described herein.

One advantage of the core construction described above is that when assembled into the electromagnetic assembly described above, each one-piece core provides a complete return path to the two stator poles formed by the legs of the U-shaped core. This eliminates the need for a back iron to magnetically interconnect all stator poles. This reduces the inductance of motors constructed with this type of core since no back iron is required. This reduces inductive assistance involving higher frequency switching of the magnetic field in the core.

Another advantage of the above configuration is that there are no parasitic spaces in the core. That is, each layer of thin film soft magnetic material has been continuously extended from one end or pole of the U-shaped magnetic pole to the opposite end or pole of the U-shaped magnetic core. Thus, this configuration orients each layer of thin film soft magnetic material in an appropriate orientation to direct magnetic flux through the core along the length of each layer of thin film soft magnetic material as illustrated by arrow 236 in FIG. 6 .

As noted above, the electric machine 202 of FIG. 2 includes 56 pairs of permanent magnets spaced evenly around the rotor assembly 204 , and each stator module 214 includes six stator segments 218 . The stator segments 218 within a given stator module 214 are arranged with specific stator segment spaces 250 between adjacent stator segments 214 . In this example, electric machine 202 is configured with a rotor pole to stator pole ratio of four to three. That is, four pairs of permanent magnets are housed within a given arc 252 of the electric machine 202 and three adjacent stator segments 218 of a given stator module are mounted within the arc 252 . Although for purposes of description, the electric machine 202 will be described as using a rotor pole to stator pole ratio of four to three, this is not a requirement. Alternatively, any desired ratio between the number of rotor poles and stator poles may be used and still remain within the scope of the present disclosure.

Arc 252 corresponds to one fourteenth of the diameter of motor 202 because four equally spaced permanent magnets are mounted within arc 252 and the motor includes a total of 56 permanent magnets 212 evenly spaced around rotor assembly 204 . This means that if the stator assembly is filled with evenly spaced stator segments within the stator segment space 250 , there is room for a total of 42 stator segments 218 surrounding the stator assembly 206 . Thus, an electric machine with a configuration of all 42 stator segments 218 may have 7 stator modules, each stator module including 6 evenly spaced stator segments 218 .

As mentioned above, the motor according to the teachings of the present invention may not use all the stator modules. Furthermore, specific stator module designs and motor designs can make it difficult to maintain a constant stator segment spacing between stator segments at the ends of adjacent stator modules. For example, the thickness of the stator module housings of two adjacent stator modules may be such that it is impossible to maintain a constant stator segment spacing between the stator segments at the ends of the adjacent stator modules. Thus, specific electric machine and stator module involvement, or the use of fewer stator modules within a particular electric machine design may result in stator pole gaps that are greater than the stator segment spacing between adjacent stator segments within the associated stator module.

In the particular embodiment of FIG. 2 , electric machine 202 includes only six evenly spaced stator modules 214 , and each stator module includes only six stator segments 218 . This results in a total of 36 stator segments in the stator assembly 206 , even though 42 stator segments would fit within the electric machine 202 when the constant stator segment space 250 uses all stator segments. In other words, 6 of a potential 42 stator segments are omitted in the electric machine 202 . Using less than all of the stator segments 218 in the stator assembly 206 creates stator pole gaps 254 between the stator segments at the ends of adjacent stator modules. The stator pole gap 254 is larger than the stator segment space 250 between adjacent stator segments in the stator module 214 . In the electric machine 202 , the stator pole gap 254 is twice the size of the stator segment space 250 because 6 potential stator segments are omitted and the 6 stator modules are evenly spaced apart from the stator assembly 206 . These larger stator pole gaps can create problems with controlling when to switch the magnetic fields of the stator segments. However, as will be discussed in detail below, these larger stator pole gaps may explain the use of control methods to modularize the design described herein.

As mentioned above, each stator segment 218 of each stator module is preferably identical to all other stator segments of all other stator modules of the electric machine. This modular construction offers several advantages over traditional electric motors.

First, by using a certain stator segment design for all stator segments of a particular electric machine, the windings and magnetic cores for the stator segments can be manufactured economically in large quantities. In the case of magnetic cores formed from thin film soft magnetic materials, this is a very clear advantage because of the difficulties associated with manufacturing magnetic cores using these types of materials. Electric motors using cores formed from thin film soft magnetic materials may offer distinct advantages over conventional iron core motors because thin film soft magnetic materials are capable of operating at very high frequencies without incurring high core losses. However, difficulties associated with using these low loss materials to manufacture magnetic cores for electric motors have previously made these materials commercially successful in electric motors.

In addition to using the same core design for all periodic sections of a particular motor, the same core design can be used for this motor family. This can be achieved by providing various winding configurations as well as various stator module housings and other components associated with the same core design. Each motor associated with the motor family may then use a core design with a specific winding configuration and a specific stator module housing. This can also increase the economies of scale associated with producing a specific core and associated motor family.

In another advantage of the modular design described above, the same motor design can be used to provide various motors with different power outputs. For example, where the electric motor is used as an in-wheel motor for an electric vehicle application, the same basic electric motor reference can be used to provide an entry-level vehicle with moderate power output, a mid-range vehicle with moderate power output, and a high-end vehicles. In a specific example of this approach, a vehicle's electric hub motor can be designed to include space for a maximum of 6 stator modules. An entry-level vehicle may be provided with two stator modules in the electric motor, a mid-range vehicle may be provided with four stator modules in the electric motor, and a high-end vehicle may be provided with six stator modules in the electric motor. This approach allows the same basic electric motor design to be used in all three power levels of the vehicle, which greatly reduces the cost of developing vehicle design and vehicle manufacturing. This approach also provides the unique ability to later upgrade the motor to a higher performance motor by adding one or more stator modules.

Most conventional electric motors are designed to run between 50 and 60 Hz, as these are the frequencies available in conventional AC grids. One reason AC power is typically provided at these frequencies is that these frequencies are within the frequency capabilities of conventional iron core motors. Even in certain prior art motors, the frequency is generally kept below 400 Hz. This is because conventional core materials cannot respond to a changing magnetic field faster than this without generating substantial losses in the form of heat.

As noted above, electric machines designed in accordance with the present disclosure may use low loss thin film soft magnetic material to form the magnetic cores of the stator segments. The use of low loss thin film soft magnetic materials for the core material of the electric motor allows operation at very high frequencies while maintaining high efficiency, and may operate at exemplary frequencies of 2500 Hz or higher.

As described with respect to FIG. 2 , electric machine 202 includes six stator modules 214a-f and electrical energy storage system 102 includes six electrical energy storage modules 104a-f. According to another aspect of the present disclosure and as illustrated in FIG. 2 , each of the stator modules 214a-f is electrically connected to a corresponding one of the electrical energy storage modules 104a-f via electrical conductors 258a-f respectively to form six separate sub-motors 260a-f. That is, stator module 214a is electrically connected to electrical energy storage module 104a using electrical conductor 258a to form sub-motor 260a, stator module 214b is electrically connected to electrical energy storage module 104b via electrical conductor 258b to form sub-motor 260b, and so on. With this configuration, each of the sub-motors 260a-f can operate independently of the other sub-motors.

As noted above, each of the electrical energy storage modules 104a-f includes an associated sub-controller 110a-f. Each sub-controller 110a-f is configured to individually control its associated power modulation circuit 106a-f and electrical energy storage module 104a-f to provide or receive power to or from its associated stator module 214a-f. Similarly, this configuration provides six electrically independent sub-motors 260a-f, each capable of independent operation relative to the other sub-motors. In this embodiment, overall master controller 110 may be used to control and coordinate the operation of sub-controllers 110a-f and sub-motors 260a-f via communication bus 112 in a manner similar to that described with respect to system 100.

In the embodiment of FIG. 2, three electrical conductors are used to electrically connect each of the electrical energy storage modules 104a-f to their associated stator modules 214a-f, respectively, since the electric machine 202 is described as a three-phase electric machine. Although motor 202 is described as a three-phase motor, this is not a requirement. Alternatively, the electric machine may have any number of phases and an appropriate number of conductors may be used to electrically connect each electrical energy storage module 104 to its associated stator module 206 .

Although the configuration of the electric machine 202 is described in detail as including a particular type of stator module having a particular type of stator segment, this is not a requirement. Alternatively, the motor may be implemented in a variety of configurations. For example, a more traditional motor configuration could be used and the windings or coils of the associated motor could be divided into a desired number of groups of windings or coils and each group associated with one of the electrical energy storage modules to form sub-motors.

As noted above, the system 200 provides an electric drive system including a plurality of independent sub-motors 260 including the stator module 214 and the electrical energy storage module 104 . In a preferred embodiment, each stator module 214 may be identical to other stator modules in the system and each electrical energy storage module 104 may be identical to other electrical energy storage modules in the system. This modular construction offers several advantages over conventional electric drive systems.

First, by using an electrical energy storage module design and a certain stator module design for a particular electric drive system, all components of the electrical energy storage module and stator module can be manufactured more economically and in higher volumes. As described above in the case of magnetic cores formed from thin film soft magnetic materials, this is a very clear advantage because of the difficulty of manufacturing magnetic cores using these types of materials.

Second, the stator modules and electrical energy storage modules can be designed to be easily removed and replaced. This can significantly improve the maintainability and reliability of this type of system compared to conventional electric drive systems by providing multiple degrees of redundancy in the system. For example, if there is a component failure (such as a short circuit in the motor windings or a battery failure), the sub-motor associated with the failed component may be shut down to operate at reduced performance compared to the total number of sub-motors Performance is directly proportional to the number of remaining sub-motors that continue to work. Shutdown of the sub-motor with the failed component allows the system to continue to operate without further risk of compromising the system, rather than requiring a complete shutdown of the entire system. This can provide significant safety in applications such as vehicle drive systems where shutting down the system due to component damage while the system is in use poses a significant safety concern. This approach can also significantly reduce the time and cost of repairs by requiring only the replacement of the failed component of the goldfish associated electrical energy storage module or stator module rather than removing and repairing or replacing the entire motor or battery pack.

As mentioned above, the same motor design can provide various motors with different power outputs by including different numbers of sub-motors. This approach also provides the unique ability to upgrade the motor to a higher performance motor by adding one or more sub-motors at a later date. Furthermore, the same electrical energy storage system design can provide various systems with different electrical energy storage capacities by including different numbers of electrical energy storage modules. As will be discussed in more detail below, this approach also provides the unique ability to upgrade the electrical energy storage system to a system with higher storage capacity by adding one or more additional electrical energy storage modules at a later date.

The modular design of the present disclosure also allows the use of smaller electrical components per motor than would be required in conventional drive systems using a battery pack and a single overall motor with similar performance levels. For example, the buck/boost converter and sub-controller associated with each sub-motor can use much smaller MOSFETs and/or other electrical components than would be required if a single total motor, controller and battery pack were used. This can reduce switching losses and can reduce the cost of electrical components by allowing the use of more common sizes that can be manufactured on a larger scale and that are more economical than less common components required by more traditional designs. Using smaller MOSFETs and/or other electrical components may also eliminate the need for factory matching components due to lower individual power levels.

As mentioned above, the use of multiple sub-motors allows the coils of the overall motor to be clustered together in a variety of ways based on the requirements of the application. This allows the motor according to the present disclosure to be configured such that each sub-motor operates at a much lower drive voltage than that used for a conventional motor with the same output. This offers significant safety advantages over conventional higher voltage electric drive systems. Furthermore, based on the specific drive voltages used for the sub-motors, smaller electrical conductors may be used to connect each electrical energy storage module to its associated stator module than would be required to connect a single large battery pack to a single large electric motor. These smaller electrical conductors can carry lower amperage and can provide additional safety advantages over conventional electric drive systems.

Another significant advantage of using the modular drive energy storage system of the present disclosure is that the correspondence of electric motors and battery packs can be substantially reduced, or even eliminated entirely. This improves the efficiency of the system by reducing or eliminating circulating currents in the motor.

Although the individual sub-controllers 110a-f of FIG. 2 are shown as being included as part of the electrical energy storage modules 104a-f, this is not a requirement. Alternatively, the sub-controllers 110a-f may be provided as discrete components point-connected at some point between the electrical energy storage module and the stator module. Alternatively, each of the sub-controllers 110a-f may be included as an integral part of their associated stator modules 214a-f, respectively, of the electric machine 202, as shown in FIG. With this configuration, electrical conductor pairs 111a-f similar to those described with respect to FIG. 1 may be used to allow electrical power to flow between each power extraction module 104a-f and their associated stator modules 214a-f. Because the sub-controllers 110a-f will generate the desired electrical phases in the stator modules, electrical conductor pairs 111a-f may be used instead of using the multi-phase specific electrical conductors 258a-f of FIG.

The methods described above can also be used to reduce or even eliminate the need for resistive balancing or other forms of balancing of groups of parallel connected series cells. As noted above, each group of parallel-connected batteries may have its own power modulation circuit, if desired, to allow each parallel-connected group of batteries to be electrically isolated from the other parallel-connected groups of batteries of the module. The power modulation circuits associated with the parallel connected battery banks can then be connected in series to provide the module operating voltage. According to this configuration, each power modulation circuit associated with each parallel-connected battery group can regulate the power stored in the associated parallel-connected battery group by discharging excess power during the use of the system or by charging the module's charger. The amount of power effectively balances the groups of batteries connected in parallel. Alternatively, the modular energy storage system of the present disclosure may be used to provide a battery management system that efficiently balances parallel-connected groups of series-connected batteries.

As shown in FIG. 8 and as described above, the electrical energy storage module 104a includes 78 cells 113 with 13 groups of 6 cells connected in parallel. In this embodiment, the electrical energy storage module 104a includes 14 sense/discharge wires 262 that are connected to the interconnected cells to sense the voltage associated with each group of parallel connected cells. The sense/discharge wire 262 is also connected to the sub-controller 110a so that the sub-controller 110a can use the sense/discharge wire 262 to independently discharge any one of the battery groups connected in parallel.

The combination of sense/discharge wires 262 and sub-controller 110a provides a balanced arrangement that is electrically connected to each of the parallel connected battery groups such that energy derived from the battery group is available from a subgroup of the parallel connected battery groups. This configuration also provides a cell balancing arrangement that can draw power from a subgroup of parallel connected batteries such that the battery module transfers energy from a subgroup of parallel connected battery groups into an electrical device or is electrically connected to the battery module other external electrical loads.

In accordance with the present disclosure, the cell balancing function described above may occur during use of the battery pack, thereby providing cell balancing functionality during normal use of the battery pack module. This allows the energy obtained from the battery during the cell balancing function to be used more efficiently than in conventional cell balancing arrangements, as the power obtained from the cell during the cell balancing function can be used to power the electrical connections to the battery pack modules and by The battery module provides power to the device.

As described above with respect to the energy storage modules 104a-f, each auxiliary electrical energy storage module may include one or more electrical energy storage components 113 for storing electrical energy. In a preferred embodiment, electrical energy storage component 113 may be a Li-ion battery having the desired Li-ion battery chemistry and battery voltage V3. While the various embodiments described herein are described as using lithium-ion batteries as the electrical energy storage component for storing electrical energy in the energy storage module, it should be understood that this is not a requirement. Alternatively, any electrical energy storage component may be used, including other types of batteries, various types of capacitors, such as ultracapacitors, an electrical energy storage flywheel, or any other electrical energy storage component.

Additionally, different auxiliary electrical energy storage modules may have different module characteristics, such as different module operating voltages. For example, where an auxiliary module includes a battery as its electrical energy storage component, the battery of one auxiliary module may have different energy storage characteristics than the battery of another auxiliary module. These features could be different lithium ion chemistries and/or different energy storage densities. Additionally, the batteries that make up each auxiliary module can be interconnected in various ways. For example, all cells of a module can be connected in series. Alternatively, the batteries making up another module can be connected in any combination of parallel and series to provide the desired module operating voltage. Where different modules of the system have different module operating voltages, each of the output arrangements may be used to convert the different module operating voltages of the different modules to the same output voltage, if desired.

As illustrated in the specific embodiment of FIG. 2 , the electric drive system 200 includes six auxiliary electric energy storage modules, which are indicated by reference numerals 280a to 280f. Each of the auxiliary modules 280a-f is electrically connected to an associated electrical energy storage module, respectively. While this embodiment shows each of the electrical energy storage modules 104a-f connected to an auxiliary electrical energy storage module, this is not a limitation. Alternatively, it is contemplated that any number of auxiliary electrical energy storage modules may be connected to each of the electrical energy storage modules 104a-f of the system.

Each of the auxiliary energy storage modules 280a-f of the electric drive system 200 includes an associated power modulation circuit, which are indicated by reference numerals 106g to 106l, respectively. As noted above, the power modulation circuits 106g - 1 may be used to electrically isolate each associated auxiliary electrical energy storage module from the other electrical energy storage modules of the electrical energy storage system 102 . Each of the power modulation circuits 106g-1 also includes an output arrangement, which are indicated by reference numerals 108g-1, respectively. Each of the output arrangements is configured to receive an auxiliary electrical energy storage module operating voltage denoted by reference numerals V5a to V5f and to convert and output an output voltage independent of the electrical energy storage module operating voltage V5a-f. In this embodiment, the output arrangements 108g-1 of the power modulation circuits 106g-1 comprise buck/boost converters 117g-1, respectively. Each of the auxiliary electrical energy storage modules 280a-f also includes associated chargers, which are indicated by reference numerals 115g through 115l, respectively. Alternatively, the charger may be provided as a separate component from the auxiliary modules or as part of the associated energy storage modules 104a-f or as part of the sub-controllers 110a-f of the electrical energy storage modules 104a-f.

Each of the auxiliary electrical energy storage modules 280a-f is electrically connected to the associated sub-controller 110a-f of the electrical energy storage modules 104a-f through a corresponding pair of electrical conductors 282a-f to allow power to be transferred between the associated modules. Each of the auxiliary electrical energy storage modules 280a-f is also electrically connected via the communication bus 112 to the sub-controllers 110a-f of the electrical energy storage modules 104a-f. This allows the sub-controllers 110a-f to control the operation of the buck/boost converters 117g-l and their associated power modulation circuits 106g-l of the auxiliary electrical energy storage modules 280a-f.

As noted above, the overall master controller 110 controls and coordinates the operation of the sub-controllers 110a-f. As the auxiliary modules are connected to the system, each of the sub-controllers is configured to control the respective power modulation circuit and its associated auxiliary electrical energy storage module and its associated buck/boost converter of the electrical energy storage module. That is, the sub-controller 110a is configured to control the power modulation circuit 106a of the modules 104a-f and the power modulation circuit 106g of the auxiliary module 280a and the buck/boost converter 117a of the control module 104a and the buck of the auxiliary module 280a / boost converter 117g. The sub-controllers 110b-f control the buck/boost converters of the power modulation circuits and their associated modules. As described above, the sub-controllers 110a-f cause each of the electrical energy storage modules and auxiliary electrical energy storage modules to output a desired electrical output at a desired output voltage V2a-f. In systems including auxiliary modules, the output voltage of a particular auxiliary module 280 may be controlled to be the same as the output voltage of its associated electrical energy storage module 104 . However, the output voltages V2a-f associated with different pairs of modules may all have the same voltage, or alternatively the output voltages V2a-f of different pairs of modules may have different voltages.

As mentioned above, this modular approach to the electrical energy storage system allows auxiliary modules to be added to increase the energy storage capacity of the system. This approach may also provide for more cost effective maintenance of the system by allowing removal and repair or replacement of individual modules rather than requiring removal and repair or replacement of the entire electrical energy storage system.

As noted above, the chemical structure of the batteries making up the auxiliary module may be different from the chemical structure of the batteries making up the energy storage module 104 . In a preferred embodiment, the auxiliary module may be a Mika composed of a high energy density battery having a higher energy storage capacity but lower power capability than the energy storage module 104 . The energy storage module 104 may consist of batteries with high power capability but low energy storage capacity. In this way, the energy storage module 104 can be used to handle any high power requirements of the system, and the auxiliary module can be stored for a longer period of time and provide a greater amount of power than a module using a higher power capability battery. Energy that can be used at a more appropriate rate.

According to another aspect of the present disclosure, each electrical energy storage module and/or auxiliary electrical energy storage module may include a module housing 284 for housing components of the modules illustrated in FIGS. 8 and 9 . The module housing 284 may include a protrusion 286 having a desired cross-sectional shape 288 having a desired length L. As shown in FIG. As illustrated in FIG. 9 , the cross-sectional shape 288 may include a peripheral wall 290 defining an opening within which all components of the electrical energy storage module may be placed and supported. As mentioned above, these electrical components may include power modulation circuits, output arrangements, sub-controllers, electrical energy storage components, chargers and buck/boost converters. The protrusions are preferably made of a thermally conductive material that allows the module housing 284 to help dissipate heat from the components of the electrical energy storage module. In a preferred embodiment, the protrusions are anodized raised aluminum, however, it should be understood that the raised material may be any desired material, such as thermally conductive plastic or any other suitable and already available materials.

The module housing 284 may include an end cap 292 (as best shown in FIG. 8 ) for sealing the end of the long lug and forming a complete closure. In a preferred embodiment, the end caps provide a watertight seal such that the module housing is hermetically sealed to protect the electrical components of the electrical energy storage module from moisture or other external elements. A potting material may be used to fill any remaining open space within the module housing and form end caps 292 to seal the electrical components within the module. A potting material may be used to support the components within the protrusion 286 and may be used to hermetically seal the electrical components within the module. The potting material may be thermally conductive to help remove heat from the electrical components of the module and non-conductive to avoid short circuits between the electrical components of the module. Alternatively, thermally conductive gap pads may be used to help remove heat from the electrical components of the module.

As best illustrated in FIG. 9 , the cross-sectional shape of the raised material 288 may include one or more of a heat dissipation surface 298 and a heat dissipation flange 296 configured to attach to a heat dissipation support. Furthermore, in embodiments where the electrical energy storage component 113 takes the form of a battery such as a lithium-ion battery, the electrical connections between the batteries included in each module may be spot welded connections, which provide the best possible connection between the batteries. Reliable electrical connection. The batteries used in each module can also be factory matched based on certain battery characteristics including, but not limited to, their battery voltage, impedance, their energy storage capacity, and/or the Any other battery characteristics.

Referring again to FIG. 1 , the present disclosure provides methods and motor controllers (eg, controller 110 ) for controlling a variable speed motor (eg, motor 118 ). The variable speed motor is powered by a power source (eg, electrical energy storage system 102 ) having a power source operating voltage (eg, module operating voltage V1a-f). The system includes a voltage varying arrangement for receiving current from a power source and a power source operating voltage, converting the operating voltage and outputting a current and a variable drive voltage that can be supplied to the electric motor and is independent of the power source operating voltage. In the embodiment of Figure 1, the voltage varying arrangement comprises buck/boost converters 117a-f. The controller also includes a switching arrangement that controls the amount of electrical energy provided to the motor by switching and applying a variable drive voltage to the motor using pulse width modulation. The switching arrangement is provided by a switching arrangement 130 on the controller 110 in the embodiment of FIG. 1 . In accordance with the present invention, the controller can vary the switching speed of the pulse width modulation and can vary the variable drive voltage in such a way that it varies according to at least the speed of the motor and/or the requested motor power output or the requested motor torque .

As described above and in accordance with the present disclosure, the controller may vary the switching speed of the pulse width modulation and may vary the voltage applied to the motor to optimize one or more operating characteristics of the electric drive system. These operating characteristics may include the efficiency of the motor, the power of the motor, the heat of the motor, the noise of the motor, the torque and speed of the motor, the life of the power supply, or any desired operating characteristic of the drive system. The controller may use predetermined functions, look-up tables, or other desired arrangements to determine the drive voltage and switching speed to use at any point within the motor's operating range.

FIG. 10 illustrates a method 300 of controlling it according to the present disclosure. As represented by step 302, the controller initially determines the current motor speed and position and the requested torque or power output. Such information may be provided by the position detection arrangement 128 via the position signal 126 and via the input signal 124 as described in FIG. 1 . Based on this information, the controller determines the drive voltage applied to the motor and the switching speed for pulse width modulation of the drive voltage, as represented by step 304 . As represented by block 306, the controller uses predetermined functions to determine the drive voltage and switching speed. These predetermined functions may take the form of look-up tables, formulas or any other suitable and already available form. Once the drive voltage and switching speed are determined, the controller causes the current and output voltage from the power supply to be converted to the predetermined drive voltage, as represented by diagram 308 . In the example of the system of FIG. 1 , the controller 110 causes the buck/boost converter 117 to receive the current from the electrical energy storage component 113 and the output voltage V2 and convert the output voltage into a predetermined driving voltage. Finally, as represented by step 310, the controller applies the drive voltage to the motor using the predetermined switching speed. This may be achieved by applying a drive voltage using a switching arrangement such as the switching arrangement 130 of Figure 1 using pulse width modulation switching at a predetermined switching speed.

Like conventional electric machines, the electric machine of the present disclosure generates a back EMF or back EMF, and the magnitude of the voltage of the back EMF is based on the rotational speed or the field switching speed of the electric machine. In general, the voltage of the back EMF increases with the field switching frequency, and thus the rotational speed of the motor increases. The back emf of a given motor is also based on the specific physical configuration of the motor. For example, the air gap between the rotor and stator poles, the magnet type and size, the type of material used to form the magnetic core, the number of turns on the coil, the interconnection arrangement of the coils, the use of back irons to magnetically connect the stator poles, and The shape and size of the magnetic core can all significantly affect the back emf of a particular machine.

11 is a graph of a single magnet cycle for a single phase of an exemplary electric machine, with voltage on the y-axis and time on the x-axis. Back EMF curve 400 illustrates the voltage of back EMF associated with this specific example of a single cycle. In this example, the cycle is divided into 40 pulse intervals of equal length, which are used for pulse width modulation of the drive voltage V6 represented by the stepped drive voltage line 402 . Each pulse interval may have an associated pulse interval voltage, such as the pulse interval voltages V6a-e of the first five pulse intervals illustrated in FIG. 11 . When the motor is driven as a motor, the driving voltage V6 can be controlled to be larger than the magnitude of the back electromotive force. Furthermore, the voltage of the pulse of drive voltage V6 can be controlled to quite closely approximate the desired optimal drive voltage curve 404 , which can, for example, be similar in shape to the back EMF curve 400 but slightly larger in magnitude.

In accordance with the present disclosure, various allowable characteristics of the motor can be optimized by controlling the shape of the stepped drive voltage line 402 of FIG. The cycle is divided into an increasing number of pulse intervals to more closely approximate the optimal drive voltage curve 404 . However, there is some energy signature associated with switching the pulse-interval voltage for each pulse interval. Therefore, there is an optimal number of pulse intervals that can be used as a function of using enough pulse intervals to get as close as possible to the motor back EMF characteristics and not applying too many pulse intervals to limit the pulses with which to switch each pulse interval. The balance of voltage-dependent switching losses for any given drive cycle of PWM,

As mentioned above, the back EMF of the motor is based on the rotational speed of the motor or the field switching frequency. Therefore, the voltage profile of the back EMF associated with a given cycle of the motor changes significantly as the speed of the motor changes. As also noted above, there may also be an optimal drive voltage profile associated with any given cycle of the motor, and this optimal drive voltage profile may be similar to and larger in magnitude than that of the back EMF. Therefore, the optimum drive voltage for a given motor can vary significantly over the motor's operating speed range.

The optimum drive voltage curve and optimum number of pulse intervals described above can be determined in various ways and remain within the scope of this disclosure. For example, a specific drive system and motor design can be thoroughly tested and characterized to determine the optimum drive voltage and switching speed for the entire operating range of the system. This may include experimental testing of specific references using various drive voltage and pulse interval combinations to determine optimum values that optimize the desired operating characteristics of the system. Alternatively, certain characteristics of the system can be measured over the entire operating range of the system and this data can be used to create formulas for calculating the optimum drive voltage profile and optimum number of pulse intervals. Some of the characteristics of the system that can be measured are those related to the switching arrangement, the back emf of the motor over the operating range of the motor, the inductance of the various components of the motor, the position and space of the stator modules, or the individual windings of the stator segment coils. Group inductance related switching losses.

This method of fully characterizing a system or machine can even be used to characterize the manufacturing tolerances of the machine within a given machine design. In this case, each individual stand-alone machine would be characterized independently to capture the implications associated with any manufacturing distinctions from machine to machine. This method can be used to account for manufacturing errors, such as air gaps between stator poles and rotor poles of different stator modules, differences in the space between stator modules and stator segments, or the resistance of groups of wound coils.

Data obtained through characteristics of the motor or system can be stored in a manner that can be used by the controller. The controller can use this data to select the desired optimum value for the drive voltage and switching speed for any given motor speed and requested power or torque input within the motor's operating range. Alternatively, data obtained by characterization of the motor or system may be used to create a formula that can be used by the controller during operation of the system. The controller can use these publications to calculate the optimum value for the desired drive voltage and requested power or torque input within the motor's operating range and switching speed for any given motor speed.

As noted above, variable speed motors including cores made of thin film soft magnetic material, such as core 220 of FIG. 4 , are capable of operating at higher field switching frequencies than motors using conventional iron cores. These field switching frequencies can be as high as 2500 Hz compared to about 60 Hz in conventional AC powered motors, or up to about 400 Hz for more specific prior art motors. Using a higher field switching frequency allows a given motor to run over a greater range of rotational speeds than would be possible if lower conventional field switching frequencies were used. While using a wider frequency range such as 0-1500Hz or higher 0-2500Hz allows a given motor configuration to have a wider range of rotational speeds, it can create some challenges and potential pitfalls if traditional motor control methods are used. Efficiency issues.

The control method of the present disclosure envisages the use of very high pulse width modulation frequencies if it can be done. This allows these methods of control to be used for motors operating at very high motor frequencies such as those described above. For example, a pulse width modulation frequency with a maximum of 100,000 Hz can be used to control a motor with a field switching operating range of 0-2500 Hz. This will allow up to 40 pulse intervals while the motor is running at its maximum field switching frequency of 2500Hz. If the same PWM switching frequency of 100,000 Hz were used when the motor was at a lower motor speed (say 100 Hz field switching frequency), this would result in 1000 pulse interval switching per motor cycle, which could create significant unnecessary switching loss.

As described above, the controller of the present disclosure varies the switching speed and drive voltage for pulse width modulation to optimize the operating characteristics of the motor. This may include using an optimum number of pulse intervals relative to the current motor frequency or speed and requested power or torque output to balance switching losses and to provide a drive voltage input as close as possible to the optimum drive voltage input curve depicted in FIG. 11 gain. Thus, in the specific example described above, when the motor is at a field switching frequency of 100 Hz, the preferred switching speed for pulse width modulation may again be 40 pulse interval switching per cycle of the motor. This would correspond to a PWM frequency of 4000Hz instead of 100,000Hz. When the motor is running at this lower speed, using this lower PWM frequency can significantly reduce the switching losses associated with running the motor at this lower speed. This can significantly help optimize certain operating characteristics of the electric machine, such as the efficiency of the electric machine. Furthermore, the optimal drive voltage curve associated with lower speed operation may have a significantly lower drive voltage magnitude than that associated with running the motor at higher speeds. Thus, as noted above, varying the drive voltage to approximate the optimum drive voltage curve associated with a given motor operating speed can also very significantly help optimize the particular operating characteristics of the motor when the motor is operating at that given speed.

Although for purposes of illustration the cycle of FIG. 11 is described as being divided into 40 equally spaced pulse intervals, this is not a requirement. Alternatively, it should be understood that each cycle may be divided into any desired number of pulse intervals and that these pulse intervals need not be the same length within any given cycle. It will be appreciated that the optimum number of pulse intervals and optimum drive voltage associated with a particular cycle of a particular motor operating at a particular frequency and desired output may vary significantly. Accordingly, the present disclosure contemplates the use of any number of pulse intervals and the use of any suitable drive voltage configuration to optimize the desired operating characteristics of the motor.

The use of low-loss core materials such as thin-film soft magnetic materials and the use of a specific core construction using a back iron without magnetic interconnects to the separate cores described above significantly reduces the reactive power of this type of motor compared to conventional motors. to the electromotive force. This smaller back emf together with the use of lower loss core materials allows for more efficient use of faster field switching frequencies. This allows a wider frequency operating range or rotational speed range. The above method of controlling it allows the use of higher PWM frequencies to accommodate this type of motor making higher frequencies available while still maintaining high efficiency at lower speeds/frequency by using lower PWM frequencies to reduce switching losses. Using a wider range of frequencies also yields a wider range of optimum drive voltages for a given motor. The lock-in control method also allows optimization of the drive voltage at any given speed over the entire operating range of the motor.

The controller described above can also be applied to a motor with multiple independent sub-motors (such as the motor 202 of FIG. 2 ). In this case, each sub-controller 110a-f can independently control its associated sub-controller using the method of controlling it described above. That is, each individual sub-controller 110a-f may vary the switching speed and drive voltage used to drive the associated stator module 214a-f to optimize the desired operating characteristics of each sub-motor. Furthermore, the varying drive voltage and switching speed used from sub-motor to sub-motor may be different for each sub-motor in order to offset any differences between the sub-motors. These differences may include, but are not limited to, the size of the air gap between the stator poles and the rotor poles, the inductance of the components making up each sub-motor, the back EMF associated with each group of stator segments making up the stator module, the motor internal Any other differences in the location of the submodules or in the characteristics of the submotors. For example, the above-described methods of fully characterizing a motor and using the data obtained from these characterizations to control the operation of the motor can be used to compensate for differences in sub-motors.

The method of fully characterizing the electric machine as above may also allow the use of a single position sensing arrangement in the electric machine to provide position signals with the phase controllers, regardless of the number of stator modules included in the electric machine. In this way, the time difference associated with the field switching of the stator poles in each of the different stator modules will be determined during the characterization of the electric machine. These time differences will be provided to the overall main controller as part of the intended function of the sub-controllers which the overall main controller uses to control the sub-motors. Using these time differences, the overall master controller can coordinate the operation of each of the sub-controllers to compensate for the various positions of the stator modules within the motor.

As mentioned above, an electric machine according to the present disclosure may not use all stator modules. Furthermore, specific stator module design and motor design can make maintaining a constant stator segment space between end stator segments of adjacent stator modules difficult. Therefore, specific electric machine and stator module designs (such as illustrated in FIG. 2 ) may result in stator pole gaps 254 that are larger than stator segment spaces 250 in electric machine 202 . The same method as described above for determining the time difference between the different stator modules can be used to compensate for these larger stator pole gaps.

The approach of using multiple sub-motors and being able to compensate for different positions of the stator modules allows each stator module to be positioned such that it can be phase shifted relative to the other stator modules. In other words, where each stator module is configured as a three-phase arrangement, each stator module may be positioned such that the three phases of the stator module are out of phase with respect to the other stator modules. This allows each stator module to effectively add three additional phases to the motor. For example, an electric motor with six stator modules each used as a three-phase arrangement can provide a total of eighteen phase arrangements. This feature can be used to provide certain advantages, such as a smoother running motor with less torque ripple.

The controller approach described above can be used to optimize a combination of features of the system or any desired operating characteristics. For example, the efficiency of the system may be an operating characteristic that is optimized during normal operation of the electric machine. Under certain high load conditions, the optimized operating characteristics may be changed to optimize the power output of the system. Other operating characteristics such as noise associated with the operation of the system or the temperature of the motor or electrical energy storage module may be detected and the controller may be configured to optimize or control these characteristics when they reach a certain level. In another example, the state of charge of the electrical energy storage system may be detected and the controller may be operated to limit the output of the drive system when the state of charge drops below a certain level.

Although the characterization of the electric machine is described above as being done prior to use of the electric machine, this is not a requirement. Alternatively, various characteristics of the motor may be monitored during use of the motor and these potentially changing characteristics may be incorporated into the characteristic data used by the controller to determine the switching speed and drive voltage to use. This allows the system to adapt or adjust to changes in the various characteristics of the motor that may change during use of the motor. These characteristics may include, but are not limited to, the temperature of the motor, the resistance of various electrical components of the motor, the impedance of various components of the motor, or any other motor characteristic. If desired, these characteristics may be continuously monitored and continuously updated and included in the characteristic data used by the controller to determine the PWM switching speed and drive voltage used by the controller to control the motor.

A number of implementations of the disclosure have been described. However, it should be understood that various modifications may be made without departing from the spirit and scope of the present disclosure.

In a first example, each stator segment of a stator module of an electric machine can have a stator segment space which does not correspond to a specific proportion with respect to the rotor pole space. In this example, each stator segment may be wired to be controlled by its associated controller or sub-controller relative to other stator segments. This would actually allow each stator segment to be associated with its own electricity. The specific characteristics of each stator segment (including air gap, inductance, resistance, space, and any other desired characteristics) can be fully characterized as described above to allow each stator segment to be specific to a specific The optimum switching speed and optimum drive voltage curves of the stator segments are controlled individually.

In another example, while the above implementation describes the motor as a radial gap, brushless DC motor, this is not required. Alternatively, any desired motor may be used, including an axial gap motor or any other suitable and already available motor. Accordingly, other implementations are within the scope of the following claims.

List of reference signs

V1a-f module operating voltage V2a-f output voltage V3 battery voltage

V4 driving voltage V5 auxiliary module operating voltage V6 driving voltage

V6a-f pulse interval voltage L length

100 power management system 102 power storage system 104a-f power storage module

106a-f power modulation circuits 108a-f output arrangement 110 controller 110a-f sub-controller

111a-f electrical conductors 112 communication bus 113 electrical energy storage component 114 power terminals

115a-f charger 116 external power supply 117a-f buck/boost converter 118 motor

120 rotor assembly 122 stator assembly 124 input signal 126 position signal

128 Position detection arrangement 130 Switching arrangement 132 Electrical conductor 200 Electric drive system

202 motor 204 rotor assembly 206 stator assembly 208 radial clearance

210 Axis of Rotation 212a-b Permanent Magnet 214a-f Stator Module 216 Dingzi Project

218a-f Stator segments 220 Magnetic core 222 Coil 224 Electrical leads

226 magnetic core ring 228 stator pole face 230 coil 232 layers 234 U-shaped layer

236 arrow 250 stator section space 252 arc 254 stator pole clearance

258a-f conductors 260a-f sub-motor 280 auxiliary module 282 electrical conductors

284 module housing 286 protruding part 288 cross-sectional shape 290 surrounding wall

292 End Cap 296 Cooling Flange 298 Cooling Surface 300 Controller Method

302 step 304 step 306 block 308 step 310 step

400 Back EMF curve 402 Stepped driving voltage curve

404 optimal driving voltage curve

Claims (45)

1. An electric energy storage system comprising: a plurality of electrical energy storage modules, wherein each electrical energy storage module has an associated operating voltage at which each electrical energy storage module is capable of outputting power at a variable current; a plurality of power modulation circuits, each power modulation circuit being electrically connected to an associated one of the electric energy storage modules, thereby allowing the associated electric energy storage module to be electrically isolated from other electric energy storage modules of the electric energy storage system, each electric power modulation circuit comprising a for receiving a current and an operating voltage of an associated electrical energy storage module, transforming the operating voltage and current, and outputting power at a voltage independent of the operating voltage of the associated electrical energy storage module; and an overall master controller electrically connected to each of said power modulation circuits of each electrical energy storage module to control the electrical output from each of said electrical energy storage modules and thereby control the electrical output of said overall electrical energy storage system . 2. The electrical energy storage system of claim 1, wherein each electrical energy storage system includes a plurality of individual batteries, each battery having an associated battery operating voltage. 3. The electrical energy storage system of claim 2, wherein the individual batteries are lithium ion batteries. 4. The electrical energy storage system according to claim 2 or 3, wherein the batteries of different electrical energy storage modules making up the electrical energy storage system have different energy storage characteristics. 5. An electrical energy storage system as claimed in claim 2, 3 or 4, wherein the batteries of different electrical energy storage modules making up the electrical energy storage system have different lithium ion chemistries and different energy storage densities. 6. An electrical energy storage system as claimed in claim 2, 3, 4 or 5, wherein the plurality of batteries making up each electrical energy storage module are all connected in series. 7. An electrical energy storage system as claimed in claim 1, 2, 3, 4, 5 or 6, wherein each power modulation circuit includes a buck/boost converter for converting the operating voltage of the associated electrical energy storage module to Conversion to a voltage that is independent of and can be higher than the operating voltage of the associated electrical energy storage module. 8. The electrical energy storage system according to claim 1, 2, 3, 4, 5, 6 or 7, wherein different electrical energy storage modules of the electrical energy storage system have different operating voltages and different energies, impedances and the different features selected for the feature group of the current-carrying capacity. 9. An electrical energy storage system as claimed in claim 1 , 2, 3, 4, 5, 6, 7 or 8, wherein said overall master controller is a motor controller and said electrical energy storage system is configured to include multiple An electrical energy storage system for an electric motor with a rotor with a rotor pole. 10. The electrical energy storage system of claim 9, wherein the electric motor is a brushless DC motor/generator. 11. An electrical energy storage system as claimed in claim 9 or 10, wherein: The overall master controller includes a plurality of independent controllers, each independent controller being electrically connected to an associated power modulation circuit to independently control the associated power modulation circuit and the associated electrical energy storage module; and The separate power modulation circuits cooperate to produce a single drive function for driving the electric motor. 12. An electrical energy storage system as claimed in claim 9 or 10, wherein: The overall master controller includes a plurality of independent controllers, each independent controller being electrically connected to an associated power modulation circuit to independently control the associated power modulation circuit and the associated electrical energy storage module; and The electric motor includes a stator having a plurality of independent stator modules, and each independent stator module includes a plurality of stator poles magnetically interacting with the rotor poles, each stator module being electrically connected to an associated independent control and thereby electrically connected to associated power modulation circuits and electrical energy storage modules to form a plurality of electrically independent sub-motors, each capable of operating independently with respect to the other sub-motors. 13. An electrical energy storage system as claimed in claim 12, wherein each stator module comprises a coil set charging said stator poles, said coil set having one or more coil sub-sets, wherein each coil sub-set is connected to a stator The different magnetic phases of the modules are associated with all the coils that make up each subgroup of coils electrically connected in series. 14. An electrical energy storage system as claimed in claim 9, 10, 11, 12 or 13, wherein the electric motor supplies power to the vehicle. 15. The electrical energy storage system of claim 14, wherein the electric motors are direct drive wheel motors. 16. An electrical energy storage system as claimed in claim 9, 10, 11, 12, 13, 14 or 15, wherein the overall master controller applies a variable drive current to the electric motor. 17. An electrical energy storage system as claimed in claim 9, 10, 11, 12, 13, 14, 15 or 16, wherein the overall master controller applies a variable drive current to the electric motor. 18. An electrical energy storage system as claimed in claim 9, 10, 11, 12, 13, 14, 15, 16 or 17, wherein said motor is a multi-phase motor and wherein Pulse width modulates the applied drive voltage and applies a variable drive voltage and current function to each phase of the motor by varying the voltage of the applied drive voltage. 19. An electrical energy storage system as claimed in claim 18, wherein said total master controller operates with the speed of said electric motor, requested electric motor power output and efficiency, response, life, smoothness and maximum available power optimized One or more of the ways in which the change is made changes the drive voltage and current functions. 20. The electrical energy storage system of claim 19, wherein said overall master controller increases said drive voltage using a predetermined function as said motor speed increases and requested motor power output increases. 21. An electrical energy storage system as claimed in claim 15, 16, 17, 18, 19 or 20, wherein said master master controller controls the drive voltage supplied to said motor by switching the drive voltage applied to said motor using pulse width modulation. The amount of electrical energy of the motor, and wherein the overall master controller varies the switching speed of the pulse width modulation in a manner that varies one or more of the requested motor power output and the speed of the motor. 22. The electrical energy storage system of claim 21 , wherein the overall master controller varies the switching speed of the pulse width modulation applied to the electric motor and the drive voltage to optimize the efficiency of the electric motor, the power of the electric motor, One or more of heat of the electric motor, noise of the electric motor, speed and torque of the electric motor, and lifetime of the electrical energy storage system. 23. The electrical energy storage system of claim 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 21 or 22 , wherein the power modulation circuitry of each electrical energy storage module and the overall master controller allow electrical energy to be released from a given electrical energy storage module only when said overall master controller requests electrical energy to be released from the given electrical energy storage module. 24. An electrical energy storage system as claimed in claim 23, wherein each power modulation circuit includes at least one pair of power terminals through which electrical energy is released from an associated electrical energy storage module, said electrical power terminals being associated with said electrical energy storage module The power modulation circuitry of the module controls to activate the power terminals and allow the release of electrical energy from a given electrical energy storage module only when the overall master controller requests electrical energy to be released from the given electrical energy storage module. 25. As claimed in claim 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 21, 22, 23 or 24 The electric energy storage system, wherein: The overall main controller includes a plurality of independent controllers, each independent controller is electrically connected to an associated power modulation circuit to independently control the associated power modulation circuit and its associated electrical energy storage module; The electrical energy storage system includes at least one auxiliary electrical energy storage module having an associated auxiliary electrical energy storage module operating voltage and an auxiliary power modulation circuit electrically isolating the auxiliary electrical energy storage module from other electrical energy storage modules of the electrical energy storage system, The auxiliary power modulation circuit includes an auxiliary electric energy storage module modulation voltage and current for receiving the auxiliary electric energy storage module, converting the operating voltage and current, and outputting an auxiliary electric energy storage module operating voltage independent of the auxiliary electric energy storage module voltage; and The at least one auxiliary electrical energy storage module is electrically connected to and controlled by an independent controller associated with a given one of the electrical energy storage modules. 26. As claimed in claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 21, 22, 23, 24 or the electrical energy storage system of 25, wherein each electrical energy storage module includes a module housing for accommodating the electrical energy storage module and associated power modulation circuitry, the module housing including a protruding section of thermally conductive material and a An end cap for sealing the end of the raised section material. 27. The electrical energy storage system of claim 26, wherein said end caps provide a watertight seal and wherein said raised material is raised aluminum having at least one heat sink flange and configured to attach to The cross-sectional shape of the heat dissipation surface of the heat dissipation support portion. 28. For use as in claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 21, 22, The power management method of the electric energy storage system described in 23, 24, 25, 26 or 27, the power management method comprising: using each power modulation circuit to receive an electrical energy storage module operating voltage and current of said associated electrical energy storage module and to convert and output a voltage independent of the operating voltage associated with the electrical energy storage module; and The overall master controller is used to control the power output from each electrical energy storage module and thereby control the electrical output of the overall electrical energy storage system. 29. A motor controller for controlling a variable speed motor powered by a power source having an electrical operating voltage, said controller comprising: a voltage varying arrangement for receiving a mains operating voltage from said power supply, converting said operating voltage and outputting a variable drive voltage applied to said motor and independent of said mains operating voltage; and a switching arrangement that switches and applies said variable drive voltage to said motor by using pulse width modulation to control the amount of electrical energy supplied to said motor, Wherein the controller varies the switching speed of the pulse width modulation and varies the variable drive voltage in a manner that varies one or more of the requested motor power output and the speed of the motor. 30. The motor controller of claim 29, wherein the controller varies the switching speed of the pulse width modulation and varies the variable drive voltage supplied to the motor to optimize motor efficiency, motor power, motor One or more of the heat generated by the motor, the noise of the motor, the speed and torque of the motor, and the life of the electrical energy storage system. 31. A controller as claimed in claim 29 or 30, wherein said controller varies said pulse width modulation as said motor speed varies and as said requested motor power output varies by using a predetermined predetermined function and change the variable drive voltage supplied to the motor. 32. A controller as claimed in claim 29, 30 or 31, wherein the power source comprises at least one lithium ion battery. 33. A method of controlling a variable speed motor powered by a power source having a power source operating voltage, the method comprising: using a controller to receive a mains operating voltage from the power supply and convert and output a variable drive voltage that is applied to the motor and is independent of the mains operating voltage; and using a controller to control the amount of electrical energy provided to the motor by switching and applying the variable drive voltage to the motor using pulse width modulation, Wherein the controller varies the switching speed of the pulse width modulation and varies the variable drive voltage in a manner that varies one or more of a requested motor power output and a speed of the motor. 34. The method of claim 33, wherein said controller varies the switching speed of said pulse width modulation and varies the variable drive voltage supplied to said motor to optimize motor efficiency, motor power, motor heat, motor One or more of noise, motor speed and torque, and electrical energy storage system life. 35. A method as claimed in claim 33 or 34, wherein the controller varies the variable voltage applied to the motor using a predetermined function as the speed of the motor varies and the requested motor power output varies. drive voltage as well as the switching speed of the PWM. 36. The method of claim 33, 34 or 35, wherein said power source comprises at least one lithium ion battery. 37. A battery module for use in an electrical energy storage system, the battery module comprising: at least one battery; and A module housing for housing the battery, the module housing comprising a protruding section of thermally conductive material and an end cap for sealing the end of the material of the protruding section. 38. The battery pack module of claim 37, wherein the end cap provides a watertight seal and wherein the raised material is raised aluminum having a heat dissipation surface including a heat dissipation surface configured to attach to a heat dissipation support. and the cross-sectional shape of at least one heat dissipation flange. 39. A battery module as claimed in claim 37 or 38, wherein the battery is a lithium ion battery. 40. A battery module as claimed in claim 37, 38 or 39, wherein the cells are all connected in series. 41. The battery module of claim 37, 38, 39 or 40, wherein the cells are electrically interconnected to provide a battery pack voltage and wherein the battery pack further comprises a power modulation circuit configured to be externally controlled Controller control such that the battery pack voltage is not available from outside the battery pack unless it is commanded by the external controller. 42. The battery module of claim 41, wherein the battery pack is configured for use in an electrical energy storage system having a plurality of battery modules and wherein the power modulation circuit is configured to allow the battery modules to fail and is electrically isolated from the system. 43. A battery module as claimed in claim 37, 38, 39, 40, 41 or 42, wherein said battery module comprises a plurality of parallel connected groups of batteries, each parallel connected group comprising at least one battery, and The battery groups connected in parallel are electrically connected in series to another group. 44. The battery module of claim 43, wherein the battery module includes a cell balancing arrangement electrically connected to each of the groups of batteries connected in parallel such that energy obtained from the battery module is derived from the Subgroups of battery groups connected in parallel are obtained. 45. The battery module of claim 44, wherein the cell balancing arrangement derives energy from a subset of the parallel connected battery packs such that during use of the battery module, the battery module is powered from A subset of the parallel connected battery packs transfers energy into an electrical device or other external electrical load electrically connected to the battery module, thereby providing batteries to the battery module during use of the battery module Balance function.