WO2007092955A2 - Scalable intelligent power supply system and method - Google Patents

Abstract

A scalable intelligent power-supply system and method capable of powering a defined load for a specified period of time is disclosed and claimed. Multiple external AC and DC inputs supply power to the system if available and required. An internal DC input from a back-up energy source is on board. The back-up energy source is scalable by adding additional energy cartridges such as batteries in racks mounted within frames of the system. The AC and DC inputs (including the internal DC input) are controlled, measured, sensed, and converted by circuitry controlled by the microprocessor into multiple AC and/or DC outputs. A microprocessor manages power input to, within, and output from the system. The performance of a Lithium-ion batteries used to power an automobile can be determined on the basis individual battery packs or individual battery cells within the packs. This enables the clusters or groups of Lithium ion batteries to be used in a vehicle such that these clusters operate and function as a 'gas' tank or more appropriately as an 'energy' tank.

Description

SCALABLE INTELLIGENT POWER SUPPLY SYSTEM AND METHOD

This patent application claims priority of United States provisional

application serial number 60/771,771 filed February 9, 2006 and United States

provisional application serial number 60/781,959 filed March 12, 2006. Priority is

also claimed to United States patent application serial no. 11672853 filed February

8, 2007 and United States patent application serial no. 11672957 Filed February 8,

2007. All of the aforementioned applications are in the name of the inventor, Karl

F. Scheucher.

FIELD OF THE INVENTION

The field of invention is in the field of intelligent power supply systems

having multiple alternating and direct current inputs and outputs and rechargeable,

interchangeable backup energy sources. Additionally, the invention is in the field

of interchangeable battery powered electric vehicle management systems which

include rechargeable, swap-able and replaceable battery packs at electric vehicle

refueling stations.

BACKGROUND OF THE INVENTION

United States Patent No. 6,465,986 B l issued October 15, 2002 discloses

battery interconnection networks electrically connected to one another to provide a

three-dimensional network of batteries. Each of the interconnection networks comprises a battery interconnection network having a plurality of individual

component batteries configured with compound series parallel connections. A

plurality of rows of individual component batteries are connected in parallel. A

plurality of columns of individual component batteries are interconnected with the

plurality of rows with each column having a plurality of individual component

batteries connected in series with an adjacent individual component battery in the

same column and electrically connected in parallel with an adjacent individual

component battery in the same row.

McDowell Research Corporation of Waco, Texas produces a Briefcase

Power System for powering transceivers with an advertised DC input range of 11

to 36 VDC and an AC input range of 95 to 270VAC at 47 to 440 Hz. No outputs

are specified in the advertisement at vvww.mcdowenresearch.com.

Automated Business Power, Inc. of Gaithersburg, Maryland produces an

Uninterruptible Power Supply Transceiver Power Unit with advertised DC input

range of 9 to 36VDC and AC input range of 85 to 270VAC at 47 to 440 Hz. Two

outputs are specified both at 26.5VDC, one at 5.25 A and one called auxiliary at

IA. Battery chemistry is not specified in the advertisement at www.abpco.com,

but indications are given that non-compatible battery types including primary

Lithium battery (BA-5590/U), NiCd (BB-590/U), NiMH (BB-390A/U) or any other non-compatible type shall not be useable.

There is a need for a light-weight intelligent energy system for use in a

variety of applications including for use in energy supply systems for homeland

defense, military, industrial and residential use. There is also a need for light¬

weight energy systems including battery systems for use in vehicles, cars, trucks,

military vehicles and the like which can be refueled by swapping individual

batteries or groups of batteries at energy filling stations much like the typical gas

stations.

SUMMARY OF THE INVENTION

The circuitry and control methodology described herein is applicable to use

of modular energy supply systems in automobiles. For instance, the control

methodology described herein may be used in connection with Lithium ion

batteries used in an automobile. In this way, the batteries may be removed from

the automobile and recharged at a service station and then replaced into the vehicle

fully charged. The batteries may be separately removed from the automobile or

they may be removed in groups. The invention as taught and described herein

enables the evaluation of individual batteries and the evaluation of the energy

remaining in the batteries at the time they are swapped out (exchanged) for fully

charged batteries. In this way a motorist can effectively refuel his or her vehicle and proceed on his or her way without worrying about stopping to charge the

batteries which is time consuming as the recharge time for Lithium ion batteries is

considerable. Having the ability to quickly swap the batteries in a Lithium ion car

enables the driver to get credit for the energy in his "gas" tank. In reality the

teachings of the instant invention enable the driver to effectively have an "energy

tank" as compared to a "gas tank."

A power supply is disclosed which includes multiple alternating current and

direct current inputs and outputs. One of the inputs is a back-up energy source

which is carried on board within the power supply. The back-up energy source

may be batteries or fuel cells. An enclosure used to house the power supply is

expandable to include additional battery racks each housed within an individual

frame of the enclosure. A power supply may also be expanded by interconnecting

separate enclosures with the use of appropriate cables.

The power supply is microprocessor controlled based on the status (voltage,

current and temperature) of the inputs including the status of the back-up energy

source, the status of converters and internal buses, and the status of the outputs.

The microprocessor manages the back-up energy source and the overall operation

of the power supply by selectively coupling system inputs, buses and outputs.

Where power sources are combined in an "or" relationship, diodes or their equivalents are used to prohibit undesirable current flows. MOSFET based

switches or their equivalents controlled by the microprocessor are used extensively

in the selective coupling of the system inputs, buses and outputs.

The power supply disclosed herein resides in one or more weatherproof

enclosures housing a battery rack having a plurality of batteries in at least one

frame portion. First and second fastening bars are affixed to the frame portion.

First and second connecting rods are attached to the first and second fastening bars

and extend therefrom; the battery rack includes a frame fastener and first and

second fastening bars interconnect with the frame fastener to secure the battery

rack to the frame. A rearward portion of the frame includes an electrical

motherboard mounted thereon. A front door portion of the frame may include one

or more vents and fans.

Alternatively, the power supply is mounted in an enclosure which includes a

plurality of frame portions connected to one another via robust hinges and latches

with weatherproof gasketing along the entire frame to frame interface surfaces. A

plurality of battery racks reside within the power supply with one rack residing in

each frame and being secured thereto. Since the frames are hinged together they

may be separated from each other for maintenance. Additional frames may be

added to allow greater power levels or extended operating time or both. Likewise one or more frames may be removed if the power level or operating time they

represent becomes superfluous. Each rack includes a plurality of batteries in

electrical communication with a motherboard which resides in the rearward-most

portion of the plurality of frame portions hinged together. The front-most frame is

a front door portion which includes vents and fans to cool the batteries and

electronics of the power supply. Other relative positions of frame modules are

possible and anticipated. For instance, vents and fans may be positioned in the

rearward-most frame. The front-most frame may contain the motherboard.

Alternatively, an intermediate frame may contain the motherboard and rearward-

most and front-most frames could both contain fans and/or vents.

A process for servicing the embodiment of the power supply which includes

a plurality of frame portions hinged together (with each frame securing an arrayed

rack of batteries) includes the steps of: unlocking the latch side of a frame from the

next adjacent frame; and, rotating the next adjacent frame about its hinged side to

expose the frame to be serviced. The next adjacent frame may be the rearward-

most frame which includes the motherboard for controlling each rack containing a

plurality of arrayed batteries. The next adjacent frame may be any frame

intermediate the rearward-most frame and the front-most frame. Each frame may

be separated from the next adjacent frame as the frames are hinged together.

Removal of the hinge pin from the hinge may accomplish the separation of the frames, or removal of fasteners retaining flanges associated with the hinges to a

frame may perform the separation, or other logical means of disconnecting framed,

door-like, hinge connected modules from one another may be employed.

Alternatively, the above described frame portions may be separately

enclosed and interconnected as required using appropriate weatherproof cable

assemblies. A rack for housing a plurality of removable cartridge batteries includes

a plurality of shelves arranged in a stack type relationship. The stack includes a

bottom shelf and a top shelf. Intermediate shelves residing between the bottom

shelf and the top shelf are vertically spaced apart from each other. The shelves

include a plurality of bores therethrough with interconnecting rods extending

vertically through the bores in the shelves. A plurality of hollow spacing tubes

(spacers) reside concentrically around the plurality of interconnecting rods and

intermediate each of the shelves spacing them apart. Fasteners, such as nuts, are

affixed to the interconnecting rods beneath the bottom shelf and above the top

shelf. Other techniques of construction are also contemplated wherein the spatial

relationship of the shelves and overall ruggedness of the structure is maintained

comparable to the above described connecting rod and spacing tube construction

technique. These other techniques may include formed sheet metal components

welded together or connected by fasteners to form a superstructure into which the

shelf elements may be placed and securely retained by features of the engagement between the sheet metal and shelf elements (snap together construction) or by

additional fasteners or other adhesive techniques.

Each of the removable cartridge type batteries includes a first electrical

contact and a second electrical contact. The removable cartridge type batteries

may be removable cordless tool batteries. Each shelf contains one or more battery

docking locations. Each docking location includes a first electrical connector

which matingly engages the first electrical contact of the battery and a second

electrical connector which matingly engages the second electrical contact. First and

second wires are affixed to the first and second electrical connectors and are routed

to a battery interface circuit. Additional contacts and corresponding electrical

contacts may be present upon batteries and docking locations.

Alternatively, the shelves may include battery interface circuits in the form

of printed circuits thereon. Each shelf includes a connector for communication with

another board, typically a rack common board which in turn connects typically to

the aforementioned motherboard. In this example the first and second connectors

engage and are electrically connected to appropriate points of each respective

printed circuit.

The power supply includes a programmable microprocessor for managing

inputs, internal components and outputs based on continuously sampled and

processed voltage, current and temperature measurements. An alternating current input source is selectively coupled to an AC/DC converter which, in turn, is

selectively coupled with an intermediate DC bus and/or a second DC bus and/or a

third DC bus. First, second, and third direct current input sources are selectively

coupled with the intermediate DC bus and/or the first DC bus and/or the second

DC bus and/or the third DC bus. The intermediate DC bus is selectively coupled

with a first DC output and/or a DC/AC inverter and/or a third DC/DC converter.

The third DC/DC converter is coupled to a second DC output and a third DC

output. The first DC bus is coupled to a first DC/DC converter which, in turn, is

selectively coupled to the intermediate DC bus and/or the third DC bus and/or a

DC charge bus.

The second DC bus is coupled to a second DC/DC converter which, in turn,

is selectively coupled to the intermediate DC bus and/or the third DC bus and/or

the DC charge bus.

The third DC bus is coupled to a fourth DC output and the third DC bus is

selectively coupled to a fourth DC/DC converter which, in turn, is coupled to a

fifth and sixth direct current output. The charge bus is coupled to the third direct

current input source. The third direct current input source is the battery back-up

current source containing literally almost any number of individual batteries.

Batteries over a wide range of inputs from 10 to 40 VDC will be used. However, it

is specifically envisioned that batteries over a wider range such as 1.5 VDC up to hundreds of volts direct current may be used provided appropriate circuit element

adaptations are made such as utilizing switches rated for the voltage ranges being

switched.

As previously stated, the power supply includes a microprocessor and the

third direct current input source includes a nearly limitless plurality of removable

cartridge battery packs. Each of the removable cartridge battery packs is selectively

connected or disconnected with a battery bus interconnected with a load. Each of

the removable cartridge battery packs is also selectively connected or disconnected

with a charge bus.

One exemplary algorithm for operation of the plurality of batteries is as

follows. The microprocessor selectively connects a first portion of the plurality of

removable cartridge battery packs with the battery bus. The microprocessor

selectively connects a second portion of the plurality of removable cartridge

battery packs with the charge bus. The microprocessor selectively connects a third

portion of the plurality of removable cartridge battery packs with both the battery

bus and the charge bus. The microprocessor selectively disconnects a fourth

portion of the plurality of removable cartridge packs from both the charge bus and

the battery bus.

The first, second, third and fourth portions of the plurality of removable

cartridge battery packs may include one, more than one, all, or none of the plurality of removable cartridge battery packs. The plurality of removable cartridge battery

packs may include batteries having different nominal voltages. "Nominal voltage"

as used herein means the voltage across a fully charged battery, namely, the open

circuit voltage.

One exemplary process for operating a power supply having a plurality of

battery packs is disclosed and includes the steps of: monitoring the battery bus

output branch associated with each of the selected battery packs and measuring the

voltages thereon while supplying a load which includes a direct current to direct

current step up converter; monitoring the battery bus output branch associated with

each of the selected battery packs and measuring the voltages thereon while

disconnected from the load; comparing the unloaded and loaded voltages of each

respective battery selected for operation and connection to the load; and,

identifying battery packs to be charged depending on the comparison of the

unloaded and loaded voltages on each of the respective battery bus output

branch(es). The process can also include the step of charging the identified battery

packs. Still additionally, the process can include the step of charging the identified

battery packs at a voltage higher than the nominal voltage of each of the battery

packs.

The battery back-up direct current input can be virtually limitless in size.

Multiple frames can house multiple racks of back-up batteries. The back-up batteries are expected to be in the range of 10 VDC to 40 VDC. Commercially

available cordless tool batteries are in this range. Therefore, the power supply

disclosed and claimed herein includes a microprocessor and up to K batteries in

parallel, where K is any positive integer. I disclose battery arrays having 20 Li-Ion

batteries per rack. In the 20 battery per rack example each battery has a nominal

unloaded voltage of 18 VDC. Each battery has a battery interface circuit which

switchably interconnects each battery with up to N loads where N is any positive

integer. Each battery is switchably connected (through the battery interface circuit)

with the charge bus. The back-up batteries are connected in parallel and may be

removed for use in another application such as in another power supply or in a

cordless tool, other cordless appliance, vehicle, or other backup energy application.

A monitor bus is also switchably interconnected by the battery interface circuit of

each battery and may monitor up to K batteries. Lastly, a sense resistor bus

switchably interconnects with up to K batteries. The microprocessor directs power

into and out of each described bus controlling up to K battery connections with up

to N load, charge, monitor, and sense buses.

The microprocessor also prioritizes up to N loads and disconnects the loads

in a prescribed order as to their relative importance at prescribed levels or

remaining energy as remaining backup energy diminishes through periods of

continuing operation. Another embodiment of the power supply includes a plurality of hot-

swappable removable cartridge battery packs in parallel interconnected with either

a DC-AC inverter or with a DC-DC converter which in turn leads to the DC-AC

inverter after the DC voltage is appropriately modified. Usually this modification

will involve a step-up of the voltage. The DC-AC inverter provides an AC output.

The removable cartridge battery packs are arranged in parallel with each other and

include a common battery bus for communicating power to the DC-AC inverter.

Each of the battery packs includes an output and a diode or equivalent circuit

substituting the diode function arranged in series with the output of the battery

pack communicating power to the common battery bus. It should be noted that

alternative circuit implementations are possible and contemplated.

The AC-DC input is fed to an AC-DC converter and then is ored together

with the output of the DC-DC converter. Alternatively, the output of the AC-DC

converter could be ored together with the common battery bus if no modification

of the common battery bus DC voltage is desired.

The output of the AC-DC converter is interconnected in series with a diode

and said common battery bus is interconnected in series with a diode and the

diodes are interconnected in an oring fashion. In this fashion the diodes or

equivalent circuits protect the common battery bus and/or the DC-DC converter

and/or the AC-DC converter from back fed current. The diodes are commonly joined in a bus which is interconnected with the DC-AC inverter.

The conceptual management hierarchy of the power supply system is

disclosed herein. Using this hierarchical arrangement the network management

user may access the status and control parameters for all subsystems under a

particular gateway. Information is shown for the batteries (energy subsystems and

energy modules), inputs, converters, and outputs (power conversion and control

units), and gateway. All aspects of the underlying power supply status and

operation may be monitored and controlled by the user via this network. Up to P

power conversion and control units may be (where P is a positive integer)

connected for management purposes to each gateway. Similarly, up to S energy

subsystems (where S is a positive integer) may be connected for management

purposes to each power conversion and control unit. Up to M energy modules

(where M is a positive integer) may be connected for management purposes to

each energy subsystem. Energy modules include but are not limited to lithium ion

based batteries.

By virtue of this hierarchical arrangement the power supply user may

configure and control a power supply systems under a particular gateway. For

example, one such physical arrangement may be a gateway unit connected to at

least one power conversion and control unit which in turn is connected to at least

one energy subsystem which in turn is connected to at least one energy module. As long as at least one energy subsystem having at least one energy module is

connected to a power conversion and control unit, the power conversion and

control unit may continue to operate provide power and management control to the

user.

It is an object of the invention to provide a power supply wherein at least

one input is a back-up energy source and wherein the back-up energy source is

rechargeable within the battery rack, is rechargeable within the rack but with the

rack removed from the power supply, or is rechargeable when removed from the

rack and from the power supply.

It is an object of the invention to provide a power supply wherein a back-up

energy source includes a rack of individually controlled and rechargeable

removable cartridge type energy packs.

It is an object of the invention to provide a power supply wherein removable

cartridge type energy packs are batteries.

It is an object of the invention to provide a power supply wherein removable

cartridge type energy packs are batteries at different voltages.

It is an object of the invention to provide a power supply capable of

receiving I (where I is a positive integer) AC or DC inputs and controlling,

measuring, sensing, charging and converting those inputs.

It is an object of the invention to provide a power supply capable of supplying Q (where Q is a positive integer) AC or DC outputs and controlling,

measuring, and sensing, those outputs.

It is an object of the invention to provide a power supply capable of

managing I AC or DC inputs and managing Q AC or DC outputs by periodically

and continuously sampling and measuring system currents, voltages and

temperatures.

It is an object of the invention to provide a power supply having I AC or DC

inputs wherein at least one of those inputs is back-up energy source which may be

a fuel cell rack, an atomic-powered generator rack, a Li-Ion battery rack, a NiMH

battery rack, a NiCd battery rack, a lead acid battery rack, a Li-Ion polymer battery

rack, or an Alkaline battery rack. It is an object to provide a microprocessor

controlled intelligent power supply which effectively manages its backup power

supply input.

It is an object of the present invention to provide a power supply having a

DC input from a plurality of removable, hot-swappable, and interchangeable

batteries which provide power on a common battery bus to a DC-AC inverter.

Alternatively, and additionally, AC power may be supplied to the power supply

through an AC-DC converter which is then converted back to AC for purposes of

reliability and for the purpose of seamless transition (uninterruptible power supply

on-line topology). The output of the DC to AC converter is arranged in a diode oring fashion together with the output from the common battery bus. The diode

oring selects the higher voltage in converting from DC to AC power. Further, the

common battery bus voltage may be converted by a DC to DC converter

intermediate the common battery bus and the diode in series leading to the junction

with the output of the AC-DC converter. Use of the DC to DC converter enables

use of rechargeable batteries which have a relatively low output voltage. It is an

object of the invention, in this example, to provide a power supply which does not

require a microprocessor to manage its operations. Rather, this example provides a

seamless transition from an AC power input to a DC power input with hot-

swappablility of the batteries. The batteries may be cordless tool batteries capable

of dual use. Further, the batteries may be Li-Ion or any of the types referred to

herein.

It is an object of the invention to enable use of batteries in an electric or

hybrid automobile such that the batteries may be interchanged and exchanged at a

service station.

It is an object of the invention to enable the use of electric vehicles by

intelligently interchanging the batteries of the vehicles at a service station.

It is an object of the invention to enable the use of electric batteries in a

vehicle such as a car wherein the electric batteries are interchanged at a service

station and credit is given for the energy left in the batteries. It is an object of the invention to enable use of electric vehicles anywhere

over long distances at high speeds without lengthy recharge periods as the batteries

may be replaced at service stations just as a gasoline powered car is fueled at a

gasoline service station.

It is an object of the invention to enable electric vehicles having batteries

arranged in series or parallel to be interchanged at a service station.

It is an object of the invention to enable continuous operation of electric

vehicles indefinitely without taking the vehicle out of service to recharge the

batteries on board.

These and other objects will be best understood when reference is made to

the following Brief Description Of The Drawings, Description of the Invention and

Claims which follow hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a front perspective view of the intelligent power supply device

illustrating a plurality of removable cartridge energy packs in a rack.

Fig. IA is a front perspective view of the intelligent power supply device

similar to Fig. 1 without the removable cartridge energy packs in the rack.

Fig. IB is a front perspective view of the intelligent power supply device

without the rack and without the removable cartridge energy packs in the rack.

Fig. 1C is a front perspective view of the rack illustrated in Figs. 1 and IA. Fig. ID is a front view of the rack partially populated with the removable

cartridge energy packs in the rack.

Fig. IE is a side view of the rack taken along the lines IE- IE of Fig. ID.

Fig. IF is a side view of the rack taken along the lines IF- IF of Fig. ID.

Fig. IG is an enlargement of a portion of Fig. ID illustrating one of the

removable cartridge energy packs in the rack.

Fig. IH is an enlargement of a portion of Fig. IF illustrating one of the

removable cartridge energy packs in the rack.

Fig. II is an illustration of one of the shelves of the rack having the battery

interface circuits on and in the shelf underneath the battery contacts/guides.

Fig. IJ is a perspective illustration of the removable cartridge energy

pack/battery pack illustrated in Fig. 1.

Fig. IK is a front view of the removable cartridge energy pack/battery pack

illustrated in Fig. 1.

Fig. IL is a side view of the removable cartridge energy pack/battery pack

illustrated in Fig. 1.

Fig. IM is a perspective view of the removable cartridge energy pack/battery

pack rack removed from the frame of the intelligent power supply device and

stored in the door enabling maintenance on the motherboard in the rear of the

device. Fig. IN is a perspective view of a modular intelligent power supply device

indicating two frames each holding a removable cartridge energy pack/battery

rack, a front cover hinged to one frame and including ventilating fans and ports,

and a rear cover hinged to another frame.

Fig. 2 is a front perspective view of the intelligent power supply device

illustrating a plurality of other removable cartridge energy packs in a second rack.

Fig. 2A is a front perspective view of the intelligent power supply device

similar to Fig. 2 without the plurality of the other removable cartridge energy

packs in the second rack.

Fig. 2B is a front perspective view of the second rack illustrated in Figs. 2

and 2 A.

Fig. 2C is another front perspective view of the second rack illustrated in

Figs. 2 and 2A.

Fig. 2D is a front view of the second rack partially populated with the

removable cartridge energy packs in the second rack.

Fig. 2E is a side view of the second rack taken along the lines 2E-2E of Fig.

2D.

Fig. 2F is a side view of the second rack taken along the lines 2F-2F of Fig.

2D.

Fig. 2G is an enlargement of a portion of Fig. 2D illustrating one of the removable cartridge energy packs in the second rack.

Fig. 2H is an enlargement of a portion of Fig. 2F illustrating one of the

removable cartridge energy packs in the second rack.

Fig. 21 is a perspective illustration of the removable cartridge energy

pack/battery pack illustrated in Fig. 2.

Fig. 2J is a front view of the removable cartridge energy pack/battery pack

illustrated in Fig. 2.

Fig. 2K is a side view of the removable cartridge energy pack/battery pack

illustrated in Fig. 2.

Fig. 2L is an example of a power supply which includes a three by three

battery array mounted in the rack along with receptacles and an on-off switch.

Fig. 3 is a schematic for controlling, measuring, sensing, charging and

converting multiple inputs (energy sources) and multiple outputs (energy loads).

Fig. 4 is a schematic illustrating: an alternating current input converted to a

direct current which is selectively switched to interconnect with a direct current

intermediate bus and/or a second direct current bus and/or a third direct current

bus; the direct current intermediate bus being selectively interconnected to a direct

current to alternating current converter providing an alternating current output

and/or the direct current intermediate bus is selectively interconnected to a first

direct current output and/or the direct current intermediate bus is selectively interconnected to a third direct current to direct current converter to provide

second and third direct current outputs.

Fig. 4A is a schematic illustrating a first direct current input, a second direct

current input and a third direct current input comprising a removable cartridge

energy pack rack direct current input, each of which is independently selectively

interconnected to the direct current intermediate bus and/or the first direct current

bus and/or the second direct current bus and/or the third direct current bus.

Fig. 4B is a schematic illustrating: the first direct current bus interconnected

with the input of a first direct current to direct current converter and the output of

the first direct current to direct current converter is selectively connected to the

direct current intermediate bus and/or the third direct current bus and/or the direct

current charge bus; the second direct current bus is interconnected with the input of

a second direct current to direct current converter and the output of the second

direct current to direct current converter is selectively interconnected to the direct

current intermediate bus and/ or the third direct current bus and/or the direct current

charge bus.

Fig. 4C is a schematic illustrating the microprocessor, its power supply and

interfaces.

Fig. 5 is a schematic of one individual microprocessor-controlled interface

circuit; each individual interface circuit controls one of the removable cartridge energy packs/battery packs and the selective interconnection with the direct current

energy pack/battery pack bus, the charge bus, the energy pack/battery pack monitor

bus and/or the energy pack/battery pack information bus.

Fig. 6 is a schematic illustration for obtaining load and removable cartridge

energy pack/battery pack information for use by the microprocessor with the load

continuously connected to the removable cartridge energy pack/battery pack and

with the load disconnected from the removable cartridge energy pack/battery pack.

Fig. 7 is a schematic illustrating up to K removable cartridge energy

packs/battery packs selectively interconnected with N load buses, a sense resistor

bus, a charge bus and a monitor bus.

Fig. 8 is an illustration of the processing steps used in a configurable power

supply control algorithm implemented using a microcontroller.

Fig 9A is a representation of intelligent power supplies connected to various

loads (wireless routers and associated devices) for the two purposes of supplying

power to the loads and interfacing to a network.

Fig. 9B is a table illustrating computer monitoring and management of the

scalable intelligent power supply management system.

Fig 10 is a schematic of the 3.3 V and 6.6V Power Supplies.

Fig. 11 is an example of a schematic similar to Fig. 5 of one individual

microprocessor-controlled interface circuit for the control of one the removable cartridge energy packs/battery packs and the selective interconnection with the

direct current energy pack/battery pack bus, the charge bus, the energy

pack/battery pack monitor bus and/or the energy pack/battery pack information

bus.

Fig. 12 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit..

Fig. 13 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 14 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 15 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 16 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 17 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 18 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 19 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit. Fig. 20 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 21 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 22 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 23 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 24 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 25 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 26 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 27 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 28 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 29 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit. Fig. 30 is an example of a schematic similar to Fig. 5 of another individual

microprocessor-controlled interface circuit.

Fig. 31 indicates an example of AC input and AC/DC converter circuits.

Fig. 32 is an example of an AC/DC converter and DC output voltage bus

connection switch.

Fig. 33 is an example of First DC input circuits.

Fig. 34 illustrates an example of First DC input bus connections switches.

Fig. 35 illustrates an example of Second DC input circuits.

Fig. 36 illustrates an example of Second DC input bus connections switches.

Fig. 37 illustrates Third DC input battery pack array circuits.

Fig. 38 illustrates the Third DC input bus connection switches.

Fig. 39 illustrates an example of First DC/DC converter circuits.

Fig. 40 illustrates an example of First DC/DC converter bus connection

switches.

Fig. 41 illustrates an example of Second DC/DC converter circuits.

Fig. 42 illustrates an example of First DC/DC converter bus connection

switches.

Fig. 43 illustrates an example of DC/AC inverter circuits.

Fig. 44 illustrate an example of First DC output circuits.

Fig. 45 illustrates an example of Third DC bus and fourth DC/DC converter circuits.

Fig. 46 illustrates an example of Fourth, Fifth, and Sixth DC outputs and

Fourth DC/DC converter circuits.

Fig. 47 illustrates an example serial to parallel circuits to implement serial

microprocessor control instructions into parallel control signals.

Fig. 48 illustrates an example of additional serial to parallel circuits

implementing the microprocessor control signals.

Fig. 49 illustrates an example of additional serial to parallel circuits

implementing the microprocessor control signals.

Fig. 50 illustrates an example of additional serial to parallel circuits

implementing the microprocessor control signals.

Fig. 51 illustrates an example of Microcontroller interface circuits.

Fig. 52 illustrates an example of Microcontroller and support circuits.

Fig. 53 illustrates an example of Microcontroller interface circuits.

Fig. 54 illustrates an example of current monitoring circuits.

Fig. 55 illustrates an example of current monitoring circuits.

Fig. 56 illustrates an example of current monitoring circuits.

Fig. 57 illustrates an example of DC/DC converter voltage programming

circuits.

Fig. 58 illustrates an example of Second and Third DC outputs and third DC/DC converter circuits.

Fig. 59A schematically illustrates twenty battery packs interconnected in

parallel to a common battery bus leading to either a DC-AC inverter or to a DC-DC

converter which subsequently is interconnected to a DC-AC inverter.

Fig. 59B schematically illustrates the interconnection of the battery array

with a DC-DC converter which is interconnected with a diode which in turn is

interconnected with a bus leading to a DC-AC inverter.

Fig. 59C schematically illustrates the interconnection of an AC input with an

AC-DC converter which in interconnected with a diode which in turn is

interconnected with a bus leading to the DC-AC inverter.

Fig. 59D pictorially illustrates the power supply with the battery rack

removed therefrom and the electronics (inverter, diodes etc.) mounted to the rear

wall of the housing or frame; also shown are two removable Lithium Ion

rechargeable battery packs.

Fig. 59E is a view similar to Fig. 59D illustrating the power supply with the

battery rack removed therefrom and further illustrating the power receptacles, the

AC input on the right hand side thereof, and the on-off switch.

Fig. 59F is a view similar to Figs. 59D and 59E with the battery rack

mounted in the housing or frame.

Fig. 59G is a view similar to the immediately preceding Figs. 59D- 59F inclusive with the battery rack populated with removable cartridge type Lithium

Ion batteries and illustrating the power supply interconnected with a load such as

wireless radio equipment.

Fig. 59H is a view similar to the immediately preceding Figs. 59D-59G

inclusive with the door of the power supply closed and illustrating the power

supply interconnected with a load such as wireless radio equipment.

Fig. 60 is an illustration of the conceptual management hierarchy of the

power supply system.

Fig. 61 A is an exemplary depiction of the physical arrangement of a power

supply system.

Fig. 61B is an alternative depiction of a physical arrangement of a power

supply system.

Fig. 62 illustrates a power supply using quick disconnect cartridge type

batteries for use in an automobile wherein the vehicles may be refueled.

A better understanding of the drawings will be had when reference is made

to the Description Of The Invention and Claims which follow hereinbelow.

DESCRIPTION OF THE INVENTION

Fig. 3 is a schematic 300 for controlling, measuring, sensing, charging and

converting 302 multiple inputs (energy sources) 301 and multiple outputs (energy

loads) 303 with some of the energy routed back 304 for further processing by the controlling, sensing, charging, and converting module 302.

Fig. 1 is a front perspective view 100 of the intelligent power supply device

illustrating a plurality of removable cartridge energy packs 102 in a rack residing

in an enclosure 101. The rack is best viewed in Figs. 1C, ID, IE and IF.

Referring again to Fig. 1 the rack is not fully populated with batteries. The

removable cartridge energy packs 102 are preferably batteries and those shown are

representative of a nominal 18 VDC Li-Ion cordless tool battery manufactured and

sold by Makita®. Makita® is believed to be a trademark of Makita Corporation of

Anjo-shi, Aichi-ken, Japan. Any type of battery may be used but Li-ion (lithium

ion), NiMH (Nickel Metal Hydride), NiCd (Nickel Cadmium), Li-ion polymer,

lead acid or alkaline batteries are presently contemplated. Li-Ion is one preferable

choice because of its gravimetric (energy per unit mass/weight) and volumetric

(energy per unit volume) efficiencies.

The United States Government (see 49 CF .R. §173.185) and the United

Nations (see 4th Edition of the Manual of Tests and Criteria) places restrictions

upon the transportation of certain lithium and lithium-ion batteries. Certain

lithium-ion batteries having a smaller capacity and therefore a lower lithium or

equivalent lithium content are exempted from these restrictions. This becomes an

advantage of the intelligent power supply design in that it preferentially

incorporates these smaller lithium-ion removable cartridge batteries. Referring, again to Fig. 1 , a partially populated rack is illustrated to

demonstrate that the power supply device will operate with at least one back-up

battery 102. The batteries 102 may be removed at any time even while they are in

operation and even while the power supply device is in operation. This is known

as being hot swappable. Reference numeral 110 indicates a printed circuit board

which contains 20 battery interface circuits thereon. Fig. 1C is a front perspective

view IOOC of the rack illustrated in Figs. 1 and IA and shows the back side of the

printed battery interface circuit board 110 attached to the shelves 103 of the rack

with screws 11OA. Alternatively, the printed battery interface circuit board may be

attached to the rack through the use of adhesives or by interlocking aspects of the

circuit board and the shelves or rack implementing a "snap together" construction.

Fig. IA is a front perspective view IOOA of the power supply device similar

to Fig. 1 illustrating the power supply device without the removable cartridge

energy packs in the rack. It is anticipated that a user would wish to run the

intelligent power supply device without populating the rack with batteries since in

fact, as explained herein, the power supply device is functional provided an

alternating current source and/or a direct current source is available. In this mode,

the power supply can serve to transform power sources on behalf of the user. For

example, a 230VAC 50Hz input can be usefully transformed by the intelligent

power supply into a 115VAC 60Hz output. See, Figs. 4, 4A, 4B and 4C. Still referring to Fig. IA, printed circuit board traces are indicated by reference numeral

HOB.

Referring to Figs. 1 and IA, shelves 103 are adapted to receive the Makita®

18 VDC Li-Ion batteries 102. Shelves 103 may be made of an electrical insulator

such as polycarbonate. Recesses 106 receive spring loaded locks 111, 112.

Reference is made to Fig. IJ, a perspective illustration 10OJ of the removable

cartridge energy pack/battery pack 102 manufactured by Makita® and which is

illustrated in Fig. 1 et seq. Fig. IK is a front view IOOK of the removable cartridge

energy pack/battery pack 102 and Fig. IL is a side view IOOL of the removable

cartridge energy pack/battery pack 102 illustrated in Fig. 1 et seq. Parts labeled

111, 112 are integral such that as button 11 1 is depressed downwardly when

viewing Fig. IJ against the force of an internal spring (not shown) tongue 112

recedes into the battery pack enabling insertion and withdrawal into the rack which

is generally denoted by reference numeral lOOC. In this way tongue 112 engages

the recess 106 of each shelf 103 and securely positions the battery into place such

that it cannot be removed even if the enclosure 101 is accidentally or purposefully

knocked over or subject to such shock and vibration as is typically present in

vehicle, aircraft, vessel, or spacecraft born applications.

Still referring to Figs. 1 and IA, front door portion 107 is shown in the open

position exposing the interior of the enclosure 101 and the interior of the door. Door 107 can be securely locked and padlocked to protect the power supply device

through known means. A threaded screw 109 is illustrated as one way to secure

the closure of the door.

Door 107 includes vents 117A which allow ventilation of the interior of the

enclosure when door 107 is closed. Filters may be placed over vents 117A to

protect from the intrusion of unwanted dust, debris, insects or other foreign

matters. Fans 117 located in the upper portion of the door 107 expel warmer air

from the device creating negative pressure thus drawing cooler air in through vents

117A. Duct or baffling elements (not shown) can be included to the effect of

directing cooler air entering via vents 117A first beneath battery rack lower shelf

103 wherefrom it flows upward across motherboard 120 (figure IB) before

traversing over top of the uppermost shelf and exiting via fans 117. In this way

cooling of power conversion elements and other electronic and electrical elements

housed on motherboard 120 is efficiently accomplished. Operation of the fans 117

is controlled by the microprocessor 495 based on various temperature

measurements. Wire harness 122 A powers fans 117.

Still referring to Figs. 1 and IA, lip 118 is affixed to door 107 and is used to

temporarily store the battery rack as illustrated in Fig. IM. Fig. IM a perspective

view IOOM of the removable cartridge energy pack/battery pack rack removed

from the frame 101 of the intelligent power supply device and stored in the door 107 enabling maintenance on the motherboard 120 in the rear of the device. Loop

118A is used in conjunction with one of the threaded interconnecting rods 104 to

secure the rack in the door. Lip 118 secures another of the threaded

interconnecting rods 104. Door open sensor 108 interacts with block 108A on door

107 to sense the position of the door. Door open sensor 108 is interconnected to

the microprocessor as indicated in Fig. 4C. In Fig. 4C the door open sensor is

schematically illustrated using reference numeral 491.

Still referring to Fig. 1, wires 139 are illustrated in conduit 138

interconnecting with enclosure 101. Wires 139 include AC and DC inputs and

outputs and communication lines. As previously indicated, microprocessor 495 is

programmable over an Ethernet connection such that once the intelligent power

supply is fixed, for example, to a pole or other bulwark and electrically connected

to a network access element such as a wireless access point via its Ethernet

connection, it may be re-programmed periodically to carry out different algorithms

or operations depending upon the management systems' commands and

requirements.

Fig. IB is a front perspective view IOOB of the intelligent power supply

device without the rack IOOC and without the removable cartridge energy packs

102 in the rack. Motherboard 120 is illustrated schematically in Fig. IB and

includes, but is not limited to: input and output circuitry; the AC/DC converter; the DC/AC inverter; the first, second, third and fourth DC/DC converters; the first,

second, third, intermediate and charge DC buses; the microprocessor;

interconnections between the microprocessor and the voltage and current sensors

on all inputs and outputs; and, interconnections between the microprocessor and

temperature sensors located in proximity to the converters.

Referring to Figs. 4, 4A, 4B and 4C, the microprocessor 495 makes voltage

measurements at all places indicated with a "V" having a circle around it.

Similarly, the microprocessor 495 makes current measurements at all places

indicated with an "I" having a circle around it. Similarly, the microprocessor 495

makes temperature measurements at all places indicated with a "T" having a circle

around it. It will be noticed that the temperature measurements are not indicated as

being directly engaging any of the converters such as 406 and 414 for example

illustrated in Fig. 4. Rather, these temperature measurements are made by sensors

on the motherboard in proximity to the device whose temperature is being

monitored. The sensors may be thermocouples, thermistors, platinum RTDs,

semiconductors (temperature sensor integrated circuits) or any other device which

indicates a change in temperature as a function of voltage and/or current. Voltage,

current and temperature interfaces (460, 461 and 462) are interposed between the

microprocessor and the sensors. The microprocessor 495 may, for example, be a

Texas Instruments mixed signal microcontroller capable of analog to digital conversion and digital to analog conversion and many other functions. Many other

microprocessors may be used instead of the Texas Instruments mixed signal

microcontroller. An onboard and/or external timebase 463 will provide a realtime

clock calendar so that time of day and date is known and it will provide a high

resolution clock so as to make accurately timed measurements of system operation.

Referring to Fig. IB, a fastening bar 124 is affixed to the enclosure 101.

Another fastening bar not shown resides above the motherboard 120. First

and second connecting rods 125, 125A are affixed to the fastening bar 124

and extend outwardly therefrom toward the front of the device. Nuts 126 are

threaded and secured to the connecting rods 125, 125A to position the rack

(generally indicated as HOC) properly within the enclosure 110. Nuts 126

limit the rearward travel of the rack so that the rack does not engage or come

too close to the motherboard.

Still referring to Fig. IB, communication and power wire harness 122 is

illustrated as extending from connector 121 to connector 123. Connector 123 joins

with connector 121 A on the printed battery interface circuit board 110.

Alternatively, wire harness 122 may transmit power and communication signals

with the individual shelves 103 A having battery interface circuits thereon. See,

Fig. II for the example of the battery interface circuits residing on the shelves

103A. Gasket 128 protects the interior of the enclosure 101 from rain, snow, other forms of moisture such as salt and fresh water spray, dust, insects, and other

foreign and possibly degrading matter.

Referring to Figs. 1C shelves 103 having apertures 106 are shown in a

stacked relationship separated by hollow tube spacers 105. Fig. II is an illustration

1001 of one of the shelves 103 A of the rack having printed battery interface circuits

(140, 141, 142, 143) on and in the shelf underneath the electrical contacts/guides

131, 132. Guides/electrical contacts 131, 132 are "L"-shaped electrically

conductive and metallic and are adapted to interfit with the Makita® battery packs

102. Referring to Fig. IJ slots 112 A, 112B engage electrical contacts 131, 132 and

include battery contacts (not shown) which conduct energy to and from the battery

102. Referring to Figs. ID, IG and IF it will be noticed that the batteries 102 rest

upon one of the shelves 103 and are spaced apart from the next adjacent shelf

above the battery. Fig. IG is an enlargement of a portion IOOG of Fig. ID

illustrating one of the removable cartridge energy packs 102 in the rack and

illustrating the gap or space 150 between the battery and the shelf. A spring loaded

lock 112 is illustrated residing in aperture 106 of the shelf in Figs. IG and IH.

Figs. ID- IH illustrate the example wherein wires 149 are used to transmit

power from the individual batteries (or other energy source) to the respective

battery interface circuit which is located on and in printed circuit board 1 10 as

illustrated in Fig. 1C, ID and IE. In the example illustrated in Figs. 1C-1F there are 20 battery interface circuits on printed circuit board 110. Another example (not

shown) houses the 20 battery interface circuits directly upon motherboard 120 with

the individual battery connections made via wires from each battery connector

location on each shelf to an appropriate connector associated with the battery

interface circuit housed upon the motherboard. Fig. 5 is a schematic 500 of one of

the microprocessor-controlled interface circuits; each individual interface circuit

controls one of the removable cartridge energy packs/battery packs 102, 202 (see,

Fig. 2) and the selective interconnection with the direct current energy pack/battery

pack bus 450A, the charge bus 489A, the energy pack/battery pack monitor bus

495A and the energy pack/battery pack information bus 495B.

Fig. IG is an enlargement of a portion IOOG of Fig. ID illustrating one of

the removable cartridge energy packs 102 in the rack. Fig. IH is an enlargement of

a portion IOOH of Fig. IF illustrating one of the removable cartridge energy packs

102 in the rack. When reference is made to Figs. IG and IH, two of the wires

referred to by reference numeral 149 are viewed connected to threaded posts 13 IA

and 132A by nuts 131B and 132B. The threaded posts and corresponding nuts also

serve the function of securing the electrical contacts against the polycarbonate

shelves. Posts 13 IA, 132A are viewed from above the shelves in Fig. 1C and

extend through the shelves and the guides/contacts 131, 132. It will also be

noticed from Fig. 1C that an additional screw (unnumbered) is threaded into the guides/contacts to secure them to the polycarbonate shelf. Figs. ID and IE

illustrate the example where the temperature sensor 133 is located in proximity to

the battery 102 and a wire(s) are connected to the sensor for communication with

the battery interface circuit. All of the wires 149 are connected to connectors 151

on the printed circuit board 110. Each shelf as viewed in Fig. IE includes 4

connectors for communication with the battery interface circuit.

Fig. II is an illustration 1001 of one of the shelves 103A of the rack having

the battery interface circuits on and in shelf underneath the battery contacts/guides.

In the example of Fig. II, the shelves are made of material suitable for the

formation of printed circuits thereon, for example, glass reinforced epoxy resin

material. Vertically extending connecting rods 104 run through bores 148 in the

shelves 103 and hollow tube spacers 105 separate the shelves from each other.

Spacers 105 are stainless steel and sufficiently strong to support the shelves.

Still referring to Fig. II, a representative temperature sensor 144 which may

be any of those referred to above is located intermediate electrical contacts 131,

132 above the 18VDC Makita® batteries. In this example the temperature sensor is

part of the printed circuit board which resides underneath the electrical contacts

131, 132. As stated previously, the Makita® battery 102 is a dual use battery

wherein it may also be used in a cordless tool application. Other batteries

including user-defined batteries may be used in a wide range of voltages and capacities. Batteries can be charged on board the rack HOC within the power

supply or on a separate charger not associated with the power supply device.

Alternatively, an entire rack of batteries may be removed from the power supply

device and connected to a special purpose external charger designed to charge any

and all of the batteries in the rack. Battery power is supplied to bus 450A and

reference numeral 147 indicates system common. Temperature sensor information

is communicated using a battery information bus 495B. A charge bus 489A is

interconnected with each battery information circuit (140, 141, 142, 143) printed

on the shelf 103A. Battery voltage information is communicated on battery

monitoring bus 495A and battery control information is communicated as

represented by line 495Z. Reference numeral 495Z represents several discrete

control enable and disable channels grouped together in combination. In the

example of Fig. II, a connector will be employed to communicate with another

printed circuit on board 110 which then communicates through connector 12 IA

back to the motherboard. Alternatively, each shelf 103 A may communicate

directly back to a connector on the motherboard as described above in descriptions

pertaining to Figs. ID - IH.

Referring to Figs. 1C, ID, IE and IF, the top-most shelf 103 is held in place

against the spacer 105 beneath it by nut 138. Other fasteners may be used to hold

the shelves in place. Fig. ID is a front view IOOD of the rack partially populated with the removable cartridge energy packs 102 in the rack. Fig. IE is a side view

IOOE of the rack taken along the lines IE-IE of Fig. ID. Fig. IF is a side view

IOOF of the rack taken along the lines 1F-1F of Fig. ID. Fastening bars 119 are

secured above the top-most shelf 103 and fastening bars 129 are secured beneath

the bottom-most shelf. Each of the fastening bars 119, 129 include bores 119A,

129A therethrough for receiving rods 125, 125 A which extend from bar 124

affixed to the enclosure 101. Additionally, fastening bars 119, 129 include bores

which allow vertical threaded interconnecting rods 104 to pass therethrough. Nuts

138, 139 secure bars 119, 129 to the shelves. With bars 119, 129 secured to the

rack and with interconnecting rods 104/spacers 105 secured in place the rack

functions as a stable and rigid unit. Bars 1 19, 129 includes bores 119A, 129A

which allow passage of rods 125, 125A therethrough as well as other rods not

shown but described herein. Rods 125, 125A protrude from the end of bars 129 as

illustrated in Figs. 1 and IA and nuts 127 are threaded onto rods 125, 125 A to

secure the rack firmly in place within the enclosure 101.

Fig. IN is a perspective view IOON a modular intelligent power supply

device having two intermediate frames 152, 152A , each of which houses and

holds a rack housing a plurality of removable cartridge energy packs/batteries. A

front cover 153 is hinged 155 to the first intermediate frame 152 and includes

ventilating fans and ports. The first intermediate frame 152 is hinged 154 to the second intermediate frame 152A. In turn, the second intermediate frame 152A is

hinged 156 to the rear cover 153 A. Rear cover 163 A includes a motherboard 160.

When fully populated the modular intelligent power supply device of the example

of Fig. IN provides twice the energy and power of the example illustrated in Fig. 1

fully populated.

Fig. IN illustrates frame 152 being partially populated and employing

shelves 103 A having the battery interface circuits printed on the underside thereof.

Frame 152 may be partially populated because some of the batteries have been

removed for use in other applications such as on a cordless tool. Or, the batteries

may have been removed for use in another power supply or they may have been

removed to enable charging on a separate stand-alone charger. It will be noted that

the modular power supply device may be taken apart for maintenance by simply

removing the hinge pin(s) holding the frame of interest. One major advantage of

the modular design is that it enables servicing of the motherboard while

maintaining (not interrupting) operation of the power supply system.

Fig. 2 is a front perspective view 200 of the intelligent power supply device

illustrating a plurality of removable cartridge energy packs 202 in a second rack.

The other removable cartridge energy packs 202 illustrated are 28 VDC Li-Ion

batteries made by Milwaukee®, a registered trademark of Milwaukee Electric Tool

Corporation of Brookfield, Wisconsin. The examples of Fig. 1 and Fig. 2 provide approximately the same energy (nominally 1000 Watt-hours) and power (150

Watts) and weigh approximately 50 pounds. The example of Fig. 2 uses 12, 28

VDC Li-ion batteries. The example of Fig. IN will provide approximately twice

the energy (nominally 2000 Watts-hours). Different power levels may be possible

in any of the described configurations. A power level of 150 Watts may be useful

for powering lighter loads such as mobile wireless routers or wireless access

points. A higher power level may be desirable for various transmitter or

transceiver communications gear, perhaps 300 to 400 Watts. These and other

power levels may be implemented via the use of appropriately sized AC/DC,

DC/DC, and DC/AC conversion units within the intelligent power supply. Larger

conversion units may require larger space within the power supply. Larger space

may be achieved in the modular approaches of Figs. 1 or IN by simply increasing

the depth of the frame containing the motherboard or by increasing the width and

height of all frame elements or both. Larger conversion units and higher power

levels may also require larger fans and greater cooling capacity. Larger fans can be

accommodated easily in any of the described design approaches by increasing the

depth of the fan and vent frame or by increasing the width and height of all frames

or both. In this way, a very wide range in the amount of backup energy and the

power level of the supply can be achieved in appropriately scaled versions of the

intelligent power supply. Again referring to Fig. IN, any number of intermediate frames may be added

to the modular power supply device to achieve the amount of backup energy

desired for a given application. In addition to the size of fans and vents being

variable, the number of fans and vents may be increased to improve cooling

capacity as the number of intermediate frames is increased as well. Power to

operate the fans is provided by cabling as indicated by reference numeral 122A.

Power supplied to and from the battery racks housed in the intermediate frames is

controlled by the battery interface circuits associated with each battery and cable

122 provides transmission of that power to and from the motherboard 160. Cable

122 also transmits control signals from the microprocessor to each battery interface

circuit. In the example of Fig. IN, fastening bars 119, 129 are fastened to each of

the intermediate frames by mounts 158 or the like. Buckle type latches 157, 157A

may be padlocked for security purposes to prevent the theft of the power supply

device or its components. The door open sensor 108 allows the microprocessor to

be informed if a door is opened. Using a network connection to a management

system the microprocessor can then inform the management entity with a door

open event alarm and can differentiate tampering versus bona fide, scheduled

service so that management personnel can respond appropriately.

Fig. 2A is a front perspective view 200A of the intelligent power supply

device similar to Fig. 2 without the plurality of the other removable cartridge energy packs in the second rack. Similar reference numerals will be used in

connection with describing the example of Fig. 2. Fig. 2B is a front perspective

view 200B of the second rack illustrated in Figs. 2 and 2A. Fig. 2C is another front

perspective view 200C of the second rack illustrated in Figs. 2 and 2A.

Referring to Fig. 2, 28 VDC removable cartridge type batteries 202 are

illustrated in a partially populated rack affixed within enclosure 201. As with the

example of Fig. 1 input and output power and communication wires 238 are

illustrated entering through an electrical conduit 238. The structural arrangement of

the rack as identified generally by reference numerals 200B, 200C is substantially

the same as the example of Fig. 1 only modified to accommodate the physically

larger batteries 202. Referring to Figs. 2B-2E, vertical connecting rods 204 pass

through bores in shelves 203. Spacers 205 reside over the vertical connecting rods

204 and support and separate the shelves 203 from each other. Spacers 205 have a

diameter larger than the diameter of the bars in the shelves 203. Fastener bars 219,

229 include bores 219A, 229A therethrough for interconnection with rods 225,

225 A for affixing the rack to the enclosure. Nuts 227 interengage the rods 225,

225A and secure the rack to the enclosure 201. There are additional bores through

the fastener bars 219, 219A for interconnection with the vertically extending

connecting rods 204. The fastener bars 219, 219A are mounted above the top shelf

and below the bottom shelf as illustrated. Rods 204 are threaded and in conjunction with nuts 238 and 239 provide a secure and stable rack which can be handled

without twisting and bending.

Door 207 operates to enable maintenance of the rack and the removal of the

batteries 202. The rack can be stored over Hp 218 by using loop 218A to secure

same and to enable maintenance on the motherboard. Fans 217, power cable

222A, vents 217A, door open switch 208A, and block 208 operates as was

explained above in connection with similar components Fig. 1. Gasket 228 keeps

unwanted rain and snow out of enclosure 201 and closure means 209 lock the door

207 to the enclosure.

Referring to Figs. 2A et seq. printed battery interface circuit board 210B is

illustrated. Reference numeral 210 is used to generally indicate the battery

interface circuit and it will be apparent to those of ordinary skill in the art that the

printed battery interface circuits (one for each battery) may reside on either the

inboard side or the outboard side of the board 210. Connector 22 IA and an

unnumbered cable are used to transmit power and control signals between the

battery interface circuits and the motherboard. Additional motherboard connectors

are used if additional racks of batteries in additional frames are employed.

Fig. 2D is a front view 200D of the second rack partially populated with the

removable cartridge energy packs 202 in the second rack. Fig. 2E is a side view

200E of the second rack taken along the lines 2E-2E of Fig. 2D. Fig. 2F is a side view 200F of the second rack taken along the lines 2F-2F of Fig. 2D.

Fig. 2G is an enlargement of a portion 200G of Fig. 2D illustrating one of

the removable cartridge energy packs 202 in the second rack. Fig. 2H is an

enlargement of a portion 200 H of Fig. 2F illustrating one of the removable

cartridge energy packs in the second rack. Battery 202 interconnects with a

Milwaukee® connector 231 and is spaced above the shelf 203 as indicated by the

reference numeral 250. The Milwaukee® 28 VDC battery 202 includes a locking

mechanism 211 which coacts with connector 231 to ensure that batteries are not

unintentionally removed from the rack. The Milwaukee® connector includes two

lips 230, 231 which support battery 202 above the shelf 203. Connector 231 is

secured to the underside of shelf 203 with screws 23 IA, 232A as is best illustrated

in Figs. 2B and 2C.

Fig. 21 is a perspective illustration 2001 of the removable cartridge energy

pack/battery pack 202 illustrated in Fig. 2. Fig. 21 illustrates a groove 23 IB which

coacts with the lips on the connector 231 illustrated in Fig. 2G. Fig. 2J is a front

view 200J of the removable cartridge energy pack/battery pack 202 illustrated in

Fig. 2. Fig. 2K is a side view 200K of the removable cartridge energy pack/battery

pack 202 illustrated in Fig. 2.

Fig. 2L is an example 200L of a power supply which includes a three by

three battery array 257 mounted in the rack 256 enclosed in weatherproof cabinet 252 along with receptacles 255 and on-off switch 254 enclosed in weatherproof

electrical box 253. Electronics are indicated with reference numeral 258.

In addition to the battery packs referenced above supplied by Makita® and

Milwaukee®, other commercially available battery packs from other application

markets are anticipated and useable as backup energy sources within the power

supply. An example of such a battery pack would be the Digital DIONIC 160®

power system offered by Anton Bauer, Inc. of Shelton, CT. In any case, a shelf

arrangement as depicted in FIG 1 and FIG 2 for specific battery pack types would

be further adapted to enable use of the Anton Bauer® or any other cartridge style

energy pack.

Fig. 5 is a schematic 500 of one of the microprocessor-controlled battery

interface circuits. An interface circuit controls one of the removable cartridge

energy packs/battery packs 102, 202 and the selective interconnection with the

direct current energy pack/battery pack bus 450A, the charge bus 489 A, the energy

pack/battery pack monitor bus 495A and the energy pack/battery pack information

bus 495B.

Still referring to Fig. 5, the microprocessor 495 multiplexes voltage signals

from the battery monitor bus 495A and, as explained previously, is capable of

converting analog to digital signals. The microprocessor enables 495E the voltage monitoring of each of K batteries in the system according to clocked signals (i.e.,

the timebase 463, see, Fig. 4C). The battery monitor bus is isolated from the

battery output/input 503 by two N-channel MOSFETs 519, 520. The monitor

enable 495E applies voltage across resistor 527 to the gate of N-channel MOSFET

526 which, in turn, divides the battery voltage across resistor 525 in proportion to

the combined resistance of resistors 524 and 525 and applies that voltage to the

gate of P-channel MOSFET 521. P-channel MOSFET 521 then allows conduction

of current through resistors 522 and 523 dividing the voltage across resistor 523 in

proportion to the combined resistance of resistors 522 and 523 and applies that

voltage to the gate of N-channel MOSFETs 519, 520 enabling the voltage to be

measured and sampled by the microprocessor 495. One exemplary P-channel

MOSFET which may be used is P channel Metal Oxide Semiconductor Field

Effect Transistor (MOSFET) made by International Rectifier. One exemplary N-

channel MOSFET which may be used is N-channel Metal Oxide Semiconductor

Field Effect Transistor made by Vishay Intertechnology, Inc. Other N-channel and

P-channel MOSFETs may be used depending on the specific application.

Still referring to Fig. 5, the microprocessor 495 generates a charge enable

495D voltage across resistor 517 which drives the gate of N-channel MOSFET 516

which divides the charge bus 489A voltage across resistor 514 in proportion the

combined resistance of resistors 514 and 515 which in turn enables P-channel MOSFET 512 allowing the application of charge bus current to the battery 102,

202 by way of battery output/input 503. Charge bus 489A is isolated from the

battery output/input 503 by a diode. A representative diode which may be used is

a Schottky Diode such as a 1OA Dual Low Vf Schottky Barrier Rectifier made by

Diodes Incorporated. Wherever such Schottky Diode applications arise within the

intelligent power supply, one may substitute an active diode oring circuit. This

type of circuit prevents reverse current flow in the same way such flow is blocked

by the diode. It has the further advantages of allowing forward current flow with a

forward voltage drop which is substantially less than the diode. The active oring

approach therefore provides diode functionality with reduced cost in terms of

system power. One exemplary implementation of the active oring alternative is

based upon a control IC such as International Rectifier's IR5001s used in

conjunction with an appropriate N-channel MOSFET.

Still referring to Fig. 5, the microprocessor 495 multiplexes battery

information signals from the battery information bus 495B and, as explained

previously, is capable of converting analog to digital signals. Reference numeral

501 indicates a voltage applied by a voltage regulator 497A. The microprocessor

de-asserts an information disable signal 495F allowing current to flow through

resistor 528 and a light emitting diode 532A coupling the output of battery 102,

202 across resistor 530 in proportion to the resistance of 530 in proportion to the combined resistance of resistors 529 and 530 which drives the gate of N-channel

MOSFET 531 effectively connecting the battery information bus 495B with a

battery information interface 530A to the effect of sensing one or more parameters

about the battery such as temperature. The battery information interface may, for

example, be a temperature sensor such as that denoted earlier by reference

numerals 133, 144. Alternatively, the battery information interface may provide

access to a more or less complex communications protocol supported by a

particular type of battery or energy pack, such protocol being based upon analog or

digital modulated or un-modulated physical signaling mechanisms in conjunction

with protocol software used to achieve higher levels of logical communications

between the microcontroller of the intelligent power supply and a peer process or

controller within the battery or energy pack. This approach allows a very wide

range of information exchange including status information from the energy pack

as well as control and command information to the energy pack to be

communicated. One known example of a communications protocol used in the

exchange of information with batteries is the SMBus. SMBus is the System

Management Bus defined by Intel® Corporation in 1995. SMBus or other possible

protocols may require multiple signals (e.g. clock and data signals). Although only

one interface signal 531 is depicted in FIG. 5 it is intended that the battery

information bus 495B may be multiple signals in width and that additional switches will be included as required to multiplex additional info bus signals when

they are used.

In addition to the obvious benefits of accessing battery information via the

battery information bus 495B, the possibility to implement security and anti-theft

functions are also important. In on scheme, energy packs (battery packs) would be

disabled and unusable whenever they are outside of and independent of the power

supply system. Using information secret to each power supply, and

communicating via the battery information bus 495B, the power supply would

selectively enable such energy packs only upon their insertion and recognition by

the system. This would effectively thwart any motivation for theft of such packs

(since they become useless once removed). Along similar lines, when the system

detects that a pack or packs have been removed as evidenced either by voltage

deficiency at the respective location on the battery monitor bus 495A or cessation

of communications at the respective location on the battery information bus 495B,

the power supply can note such removals and report same as an alarm or

information event to its network management entities. Finally, the insertion of

unauthorized or counterfeit packs may similarly be detected and reported.

Still referring to Fig. 5, reference numeral 501 is a voltage source from the

voltage regulator 497A and the microprocessor 495 generates a power enable 495C

voltage across resistor 511 voltage to drive the gate of N-channel MOSFET 507 allowing the division of battery voltage across resistor 510 in proportion to the sum

of the resistance of resistor 509 and resistor 510. The divided voltage is applied to

the gate of P-channel MOSFET 508 permitting conduction of current from the

battery output/input 503 to the direct current battery bus 450A. In general, the

switching circuit just described using MOSFETs 507 and 508 in conjunction with

various resistors, voltage sources, and control signals is representative of one

implementation for switching functions depicted in other parts of the figures such

as elements 413 and 425 in Fig. 4 and even elements 550 and 550A in Fig. 5 itself.

Diode 505 permits forward current in the direction of the dc battery bus only and

could be implemented at least using either the Schottky Diode or active oring

circuits mentioned previously in conjunction with the discussion surrounding

charge bus 489A.

Still referring to Fig. 5, a switch 550 is schematically indicated as

interconnected with Rsense bus 560. A Kth battery interface circuit is illustrated as

being connected to the DC Battery Bus 450A to emphasize that there are K battery

interface circuits. The Kth battery is also interconnected via switch 550A to

Rsense bus 560.

The structure and function disclosed herein can be used in automobiles and

other vehicles. Specifically, the structure and function of the instant invention can

monitor the performance of a Lithium-ion powered automobile to determine the performance of individual battery packs or individual battery cells within the

packs. This enables the clusters or groups of Lithium ion batteries to be used in a

vehicle such that these clusters operate and function as a "gas" tank or more

appropriately as an "energy" tank. The microprocessor used herein notifies the

driver of the status of his energy tank thus informing the driver that it is time to

refuel. The driver then stops at a service station where one or more of his battery

packs is removed from his vehicle and exchanged with freshly charged battery

packs or groups or clusters of battery packs. The driver is given credit for the

energy stored within his packs or clusters or groups of battery packs. In this way-

operation of battery powered electric vehicles becomes just like operation of a

gasoline driven vehicle.

All of the switching (selectively coupling) performed by the battery interface

circuits is programmable with respect to operation of the rack of batteries and also

with respect to other system inputs and outputs.

Fig. 7 is a schematic 700 illustrating up to K removable cartridge energy

packs/battery packs 701, 702, 703 selectively interconnected with N load buses

706, 707, 708, a sense resistor 603, an Rsense bus 560, a charge bus 489A and a

monitor bus 495A. A plurality of switches 710 are shown each of which is

controlled by microprocessor 495. MCU 495 receives inputs as described

previously in connection with Fig. 5 and also receives inputs as indicated schematically in connection with Figs. 4, 4A, 4B and 4C including voltage,

current, and temperature inputs. Fig. 7 also illustrates diodes 711 to inhibit reverse

current flow with respect to each load bus 706, 707, 708 and the charge bus 489A.

The load buses 706, 707, 708 may be selectively disconnected from the load by the

microprocessor.

Fig. 6 is a schematic 600 for obtaining load and removable cartridge energy

pack/battery pack 102, 202 information for use by the microprocessor 495.

Battery 102, 202 includes an energy source Vbat 607 and an internal resistance Re

608. Monitor 602 measures the terminal output voltage across the battery 102,

202. The battery 102, 202 is selectively interconnected (coupled) by switch 604

with a user defined load or loads 601 and is also selectively interconnected

(coupled) by switch 605 with a sense resistor 603 of known resistance.

Still referring to Fig. 6, three measurement processes are implemented. In

the first process or first algorithm, the battery 102 is selectively connected to and

disconnected from the user defined load 601 using switch 604. Voltage

measurements are made by the voltage monitor 602 with switch 604 closed to

obtain the voltage across the user defined load (Vcc- voltage closed circuit user

defined load) and with the switch open to obtain the terminal output voltage across

the battery 102 (Voc, voltage open circuit). In this process switch 605 disconnects

sense resistor 603 from the battery 102 at all times. Still referring to Fig. 6, in the second process or second algorithm, the user

defined load 601 is selectively disconnected by switch 604 from the battery 102

while voltage measures are being taken. Voltage measurements are made by the

voltage monitor 602 with switch 605 closed (Vcc-sr, voltage closed circuit-sense

resistor) and voltage measurements are made by the voltage monitor 602 with the

switch 605 open (Voc, voltage open circuit).

Still referring to Fig. 6, in the third process or third algorithm, the user

defined load 601 is selectively connected to the battery by switch 604 at all times.

Switch 605 is selectively connected to and disconnected from the sense resistor

603 using switch 605. Voltage measurements are made across the sense resistor

603 in parallel with the user defined load Vcc(sr || ul)( voltage closed circuit, sense

resistor || user defined load) when the switch 605 is closed. Voltage measurements

are also made across the user defined load Vcc(ul)( voltage closed circuit-user

defined load) when switch 605 is open.

In the first and second algorithms the closed circuit current, for example, the

load current (Ice) may be obtained by:

(1) Vload=Vbat-Vrbat

where Vload = Vcc(ul)(voltage closed circuit-user defined load) or where

Vload=Vcc(sr)(voltage closed circuit-sense resistor) and Vrbat is the voltage drop

across Re during the condition when Vload is established, and where Vbat=Voc, substituting

(2) Voc-Vcc=Vrbat

assuming Rbat (Re) is known, dividing

(3) Vrbat/Rbat=Icc

Alternatively, assuming the load current, Iload, whether it be through the

user defined load (ul) or the sensor resistor load (sr), is known, then

(4) Re=(VoC- Vcc(ul)/Iload or, Re= (Voc - Vcc(sr))/Iload

In the third algorithm, Rbat (Re) and Rsense (Rs) are known from prior

determination. We measure Vcc(ul) (voltage closed circuit-user defined load) and

Vcc(sr Il ul) (voltage closed circuit, sense resistor || user defined load). Icc(ul)

(current through the user defined load) is determined as follows:

(5) Vcc(ul)=Vbat*Rload/(Rload+Rbat)

and,

(6) Vcc(ul Il sr)=Vbat*(Rload || Rsense)/((Rload || Rsense) +Rbat), where

(7) Rload Il Rsense=Rload*Rsense/(Rload + Rsense), solving for Rload

(8) Rload= Rbat*(Vcc(ul)-Vcc(sr || ul)) / [Vcc(sr || ul) (1+Rbat/Rsense)-

Vcc(ul)], and, once Rload is known then the current through the load and the

battery can be determined by dividing Vcc^Fj/Rload^Iload.

The current through the parallel combination of Rsense and Rload can be

calculated by: (9) Icc(ul Il sr) = Vcc(ul || sr)/(Road*Rsense/(Road + Rsense)

In the third algorithm, if the load current, Iload, through Rload is known by

measurement, then Rload can be calculated by:

(10) Vcc(ul)/Icc(ul)=Rload, and once Rload is known, then Rbat=Re can be

calculated from equation 8 if Vcc(ul), Vcc(sr ||ul) and Rsense are known.

If the current through the user defined load is known and if the internal

resistance of the battery, Re, is known then a calculation of the voltage drop across

the internal resistance of the battery can be made. Batteries, and in particular Li-

Ion batteries, may be damaged if they are operated below a critical voltage which

inferentially indicates that the state of charge is too low. Current flow through the

battery, therefore, provides valuable information about the battery enabling the

user or system to decide whether a measured terminal voltage is due to a high load

or is due to a low state of charge operation. Li-Ion batteries which are drained

below a protective state of charge may be permanently damaged. Therefore, the

microprocessor may selectively disconnect a particular back-up battery if its state

of charge is too low. The microprocessor may decide to charge the particular

battery if its state of charge is approaching a critical value or the microprocessor

may supply charge current which is summed with the current available from the

particular battery of interest and continue the contribution (albeit diminished now

by the amount of the added charge current) of that battery as an energy source. If the discharge current through the load, Iload, is known or if the charge

current into a battery, Icharge, is known by a current measuring device then Re can

be determined as indicated above. Re is important because it varies as a function

of temperature, age, and other conditions of the battery and may indicate trouble

with or end of life for the battery. Therefore, the microprocessor may selectively

disable a particular back-up battery depending on a calculated Re, or the

microprocessor may signal an alarm event to inform the network management

entity of the inferred problem with a particular battery. An intermediate possibility

exists wherein the microprocessor deploys or uses (connects to loads) each battery

with a duty cycle proportional in some predictable way to the inferred health of

each battery. For example, an older failing battery will be used seldom (but not go

completely unused) compared to a brand new battery having maximal energy

which will be used often and preferentially. In this way, for a given population of

K batteries in the system, the microprocessor may proceed to deploy these batteries

in such a way that tends to equalize the health or electrical status of all. Another

valuable function of the system rests on the microprocessor's ability, via the

measurements of voltage, current, and temperature, to estimate the absolute

capacity of each particular battery or energy source during a discharge followed by

a charge cycle. The microprocessor can connect a particular battery to a load until

such time as its state of charge is seen to be approaching 0% (fully discharged). From that point, the microprocessor can disconnect said battery from the load and

connect said battery to the charge bus. The microprocessor can monitor the current

over the time of charge of the particular battery until an appropriate charge

termination event such as a voltage or temperature event indicates completion of

charge and arrival by the battery at the 100% state of charge level. The record of

current multiplied by time increment during the charge cycle then indicates the

electric charge imparted to the battery in the transformation from 0% to 100% state

of charge. In the case of a coulombic efficient battery chemistry such as lithium-

ion, the charge transferred will rather directly reflect the charge capacity at 100%

state of charge. This capacity compared to the corresponding capacity of a new,

unused battery will in turn reflect the age or conversely remaining useful life of the

battery. For example, when the battery charge capacity at 100% state of charge

falls below 50% or the new charge capacity, the battery may be nearing the end of

its useful life. In other cases where the chemistry is not 100% charge efficient, the

100% state of charge energy will nonetheless provide insight and inference into the

state of health of the battery. As mentioned earlier, in either case whether the

battery chemistry is charge efficient or not, estimation of the inherent resistance of

the battery (Re) in light of the prevailing temperature of the battery will also

provide valuable inference into the state of health of the battery.

Fig. 4 is a schematic 400 illustrating an alternating current input 401 converted to a direct current by an AC/DC converter 406. The output 406A of the

converter 406 is selectively switched by switch 407 to interconnect with a direct

current intermediate bus 412B and/or is selectively switched by switch 408 to a

second direct current bus 412A and/or is selectively switched to a third direct

current bus 412C by switch 409. Output 406A of the converter is coupled via

connection 403 to the MCU 495 (see, Fig. 4C).

All of the elements indicated and described on Figs. 4, 4A, 4B and 4C are

mounted on the motherboard (printed circuit board). All of the elements are

scalable. For instance, one example of the system may provide 1000 Watt-hours of

energy and can supply power nominally at 150 Watts. Another example may

supply 4000 Watt-hours of energy and can supply power at 800 Watts, etc.

Still referring to Fig. 4, diode 423 ensures that current flows from the output

of the AC/DC converter to the direct current intermediate bus 412B but not the

reverse. Diodes 410 and 411 similarly ensure that current flows from the output of

the AC/DC converter to the second direct current bus 412A and the third direct

current bus 412C, respectively, but inhibits flow in the reverse direction. The AC

input is converted using AC detect 404 into a direct current voltage to which

microprocessor 495 is selectively coupled to measure allowing the voltage 405 of

the AC input to be thereby estimated. Current flowing through the AC input 401 is

sensed by a current detector and microprocessor 495 is selectively coupled to measure the current 405A. The output 406A of the AC/DC converter is selectively

coupled to the microprocessor to measure the voltage 412.

The AC/DC converter may for example be a 150 Watt enclosed single out

switcher capable of accepting 85-264 VAC input with a 24 VDC output,

manufactured by Cosel. Other AC/DC converters may be used which are capable

of converting a larger or smaller VAC input and are capable of producing much

higher or lower VDC outputs at much higher or lower wattage. Virtually any AC

input may be accepted by the power supply device and converter with a properly

selected converter.

Still referring to Fig. 4, the current output of the AC/DC converter 406 is

sensed and selectively coupled to the microprocessor to measure the current 412D.

A temperature sensor may be located on the motherboard in proximity to the

AC/DC converter and is selectively coupled with the microprocessor to measure

the temperature 412E.

The direct current bus may operate over a wide range of voltages and

currents as determined by user specifications and the requirements of a particular

application. Typical voltages of the direct current intermediate bus 412 are

expected to be in the 12-30VDC range to enable supply of the intermediate bus not

only from an AC/DC converter but also from back-up energy sources such as

removable cartridge direct current batteries which may or may not be dual purpose batteries.

Still referring to Fig. 4, the direct current intermediate bus 412B is

selectively interconnected by switch 413 to a direct current to alternating current

converter 414 providing an alternating current output 417 and/or the direct current

intermediate bus 412B is selectively coupled by switch 425 to a first direct current

output 421 and/or the direct current intermediate bus is selectively coupled via

switch 425A to a third direct current to direct current converter 427 to provide

second 426 and third 428 direct current outputs. Voltage output 424, current

output 424A and temperature 424B of the direct current to direct current converter

427 are monitored by the microprocessor. The input voltage 419 to the direct

current to alternating current converter is monitored by the microprocessor 495.

The alternating current output voltage 416 of converter 414 is converted by

detector 415 and monitored by the microprocessor, as is the output current 416A.

Temperature 416B of the direct current to alternating current converter 414 is also

monitored by the microprocessor. The voltage 420 and current 420A of the first

421 direct current output are monitored by microprocessor 495.

The direct current to direct current converters may, for example be 10-32

VDC converters supplied by ACON. The AC/DC inverter may be a 150 Watt

inverter supplied by CD Media Corp.

When the phrase "monitored by the microprocessor" is used herein it means that the microprocessor 495 converts a parameter such as voltage, current or

temperature from an analog to a digital signal and then processes that signal data

according to a well defined algorithm.

Selective coupling or connection is accomplished by the microprocessor and

its control of the switches which interconnect the buses to the sources. As

described above, the output of the AC/DC converter is bused 406A to switches

407, 408 and 409 in parallel leading to respective buses. The microprocessor

controls switches 407, 408 and 409 (which may be implemented using P-channel

MOSFETS or other suitable electronic or mechanical switches) according to

system voltages, currents and temperatures of the inputs (including the back up

batteries), outputs, buses, and converters according to pre-defined programming or

specified manual control. For instance, there may be situations when the user

defines to preferentially use a particular input despite the availability of other

inputs. An example may be a military application where it is decided to use the

back up batteries as the energy source despite the availability of a direct current

source from a vehicle so as to not deplete the batteries of the vehicle in a combat

situation. As a further example, the microprocessor may infer from the level of the

DC input representing the vehicle input whether or not the vehicle is running and

correspondingly whether or not the vehicle's charging circuit is actively supplying

current. With this information, the system can implement a control plan wherein the power supply load is sourced by the vehicle when it is running, by the backup

batteries when the vehicle is not running, and then again by the non-running

vehicle battery after the backup batteries are depleted to a specified level (say 5%

state of charge). Finally, the load can be disconnected when both the vehicle and

backup batteries have reached a pre-defined low state of charge. In this way, the

intelligent power supply has maximized the run time of the load while maintaining

the best disposition of vehicle reserve battery energy, and in the end, at least

sufficient residual vehicle battery energy to guarantee the ability to start the

vehicle.

Fig. 4A is a schematic 400A of a first 430 direct current input, a second 439

direct current input and a third direct current input 450A (battery pack array) each

of which is selectively coupled to the direct current intermediate bus 412B, and/or

the first direct current bus 412J and/or, the second direct current bus 412A and/or

the third direct current bus 412C. The first direct current input 430 is bused 430A

and is selectively coupled by switch 431 with the direct current intermediate bus

412B and/or is selectively coupled via switch 432 with the first direct current bus

412J and/or is selectively coupled by switch 432A with the second direct current

bus 412A and/or is selectively coupled by switch 433 with the third direct current

bus 412C. Diodes 434, 435, 436, and 437 are located downstream from their

respective switches and ensure current flow from bus 430A to the respective buses and not the other way around. Voltage 438 and current 438 A supplied by the first

direct current input 430 is monitored by the microprocessor 495.

Third direct current input is a battery pack described herein above in regard

to Figs. 1, 2, 5, 6 and 7. An array of batteries arranged in parallel supplies power

to bus 450B. The individual batteries may be of different individual voltages and

chemistries and their use is controlled by the battery interface circuits described

above employing a selective coupling system together with diode protection.

Still referring to Fig. 4A, the third direct current input 450A is bused 450B

and is selectively coupled by switch 451 with the direct current intermediate bus

412B and/ or is selectively coupled by switch 452 with the first direct current bus

412J and/or is selectively coupled by switch 453 with the second direct current bus

412A and/or is selectively coupled by switch 454 with the third direct current bus

412C. Diodes 455, 456, 457, and 458 are located downstream from their

respective switches and ensure current flow from bus 450B to the respective buses

but inhibit the reverse flow. The switches may be P-channel MOSFETs and the

diodes may be Schottky diodes. Voltage 459 and current 459A supplied by the

third direct current input 450A is monitored by the microprocessor 495. Each of

the direct current inputs 430, 439, 450A. The AC/DC converter 406 and the first

and second converters 475, 483 are protected against over-current and over-voltage

conditions using devices such as fuses or PTC thermistor devices and Metal Oxide Varistars (MOVs) or other transient voltage suppression techniques.

Still referring to Fig. 4A, charge bus 489A is interconnected with the third

direct current input so as to enable selective recharging or load sharing as

described above in connection with Fig. 5, the battery interface circuit.

Still referring to Fig. 4A, the second direct current input 439 is bused (439A)

and is selectively coupled by switch 440 with the direct current intermediate bus

412B and/ or is selectively coupled by switch 441 with the first direct current bus

412 J and/or is selectively coupled by switch 442 with the second direct current bus

412A and/or is selectively coupled by switch 443 with the third direct current bus

412C. Diodes 444, 445, 446, and 447 are located downstream from their

respective switches and ensure current flow from bus 439A to the respective buses

but not in the reverse direction. The switches may be P-channel MOSFETs and the

diodes may be Schottky diodes. Voltage 448 and current 448A supplied by the

third direct current input 450A is monitored by the microprocessor 495.

Still referring to Fig. 4A, third direct current bus 412C is coupled to fourth

direct current output 470 and its output voltage 470A and current 470B are

monitored by the microprocessor 495. The third direct current bus 412C may also

be selectively coupled via switch 474 to the fourth direct current to direct current

converter 473 which outputs to the fifth 471 and sixth 472 direct current outputs.

Voltage 473 A and current 473B and the temperature 473E of the converter 473 are monitored by the microprocessor 495.

Fig. 4B is a schematic 400B illustrating the first direct current bus 412J

interconnected with a first direct current to direct current converter 475 and the

output 475 A of the first direct current to direct current converter 475 selectively

coupled to the direct current intermediate bus 412B and/or the third direct current

bus 412C and/or the direct current charge bus 489A. The output bus 475 A is

selectively coupled via switch 477 with the direct current intermediate bus 412B

and/or is selectively coupled via switch 478 with the third direct current bus 412C

and/ or is selectively coupled via switch 479 with the direct current charge bus

489A. Diodes 480, 480A, and 481 are located downstream from their respective

switches and ensure unidirectional current flow from bus 475A to the respective

buses. The switches may be P-channel MOSFETs and the diodes may be Schottky

diodes. Voltage 482 and current 482A of the first direct current to direct current

converter 475 as well as temperature 482E in the proximity of the converter are

monitored by the microprocessor 495.

Still referring to Fig. 4B, the second direct current bus 412A is

interconnected with the input of a second direct current to direct current converter

483 and the output 483A of the second direct current to direct current converter

483 is selectively interconnected to the direct current intermediate bus 412B and/or

the third direct current bus 412C and/or the direct current charge bus 489. The output bus 483A and is selectively coupled via switch 484 with the direct current

intermediate bus 412B and/or is selectively coupled via switch 485 with the third

direct current bus 412C and/or is selectively coupled via switch 486 with the direct

current charge bus 489A. Diodes 484, 485, and 486 are located downstream from

their respective switches allowing current to flow from bus 483 A only in the

direction of the respective buses 412B, 412C, and 489A. Once again, the switches

may be P-channel MOSFETs and the diodes may be Schottky diodes. Voltage 490

and current 490A of the second direct current to direct current converter 483 as

well as temperature 490A in the proximity of the converter are monitored by the

microprocessor 495. The charge bus 489A is interconnected with the removable

cartridge energy pack rack.

Again referring to Fig. 4B, it can be seen that microprocessor 495 has the

ability via converter output voltage control interface 495X to control the output

voltage of DC/DC converter elements 475 and 483. The microprocessor can

decide, upon measuring the voltages and currents in different channels within the

system, a best output voltage adjustment for each DC/DC converter such that the

mix of power provided by each channel is thereby optimized according to some

pre-defined goal of the system. For example, a goal of utilizing 30% current from

first DC input 430 along with 70% current from third DC input representing

backup batteries 450A can be realized by switching first DC input to power first DC/DC converter, switching third DC input to power second DC/DC converter,

and adjusting first DC converter voltage output and second DC converter voltage

output up or down as required so that the current sensed at 482A compared to the

current sensed at 490A are in the proportions 3:7. The scenario described is one

from the category of control algorithms allowing intelligent power mixing. As

compared to an all or nothing contribution decision represented by a simple switch,

power mixing allows a continuum of adjustments regarding how much power is

utilized from each source.

The converter voltage output control can be further understood by viewing

Fig. 52 signals DAC_DATA, DAC_SCLK, and DAC_SYNC_1 emanate from U34

MCU and go to Fig. 57 D l DAC (Digital to Analog Converter) U50 where four

analog voltage outputs are generated, DAC_DC1_TRIM_1 through

DAC_DC4_TRIM_1. These signals route for amplification to respective amplifier

circuits U48, U49, U51, and U52. These amplifiers in turn generate voltage

control output signals DC1_TRIM_1 through DC4_TRIM_1. These signals

connect to the respective DCDC converter TRIM input pins on Fig 39 (DCDCl U3

or U4) Fig. 41 (DCDC2 U5 or U6) Fig. 58 (DCDC3 U57) and Fig. 46 (DCDC4

UI l).

Power mixing is important as one or more direct current to direct current

converters are arranged in an oring fashion. For example, a user defined direct current input source may be combined with the arrayed battery direct current input

source comprising a plurality of batteries for the purpose of supplying one or more

user selected loads in parallel. A first direct current to direct current converter may

be coupled with the user defined direct current input source and a second direct

current to direct current converter may coupled with the arrayed battery direct

current input source, and, as just described the first and second converters have

adjustable output voltages.

A microprocessor coupled to the first and second converters controls the

output voltages of the converters and the contribution of each of the direct current

sources to the energy flowing on the DC bus(es) fed by both converters.

Secondly, the converters may be coupled together as illustrated in Fig. 4B using

diodes such as Schottky diodes. Since the microprocessor measures the current

and voltage output by each converter as well as the current and voltage of the

respective inputs supplying said converters, it is possible for the microprocessor to

adjust the output voltages of each converter to achieve several end goals including

controlling the current, voltage, or power of each input, controlling the current,

voltage, power, or temperature of each converter, and/or controlling the current,

voltage, or power of the load bus(es). Finally, since the voltages of the converters

are controlled according to net input, converter, or load characteristics measured by

the microprocessor on a continuous basis, the control process will cancel out varying characteristics such as forward voltage drop of the diodes or varying

characteristics of the converters of other components employed in the circuits.

That is to say that the control process has the advantages of a closed loop process

running to measured as opposed to predicted response variables.

The functions of measuring currents in the respective input, conversion, and

output channels is further illuminated. Shunt resistors are placed in the negative

leg of the component whose current is to be measured, e.g. Fig. 46 UI l pin 8

(VOUT_Negative) connects to point DCDC4_OUT_N. At Fig. 56 this signal

connects to GROUND via a shunt resistance formed by resistors R207 and R208 in

parallel (0.0025 ohms net). The small voltage developed across this shunt

resistance is proportional to the current flowing and is amplified in the example by

differential amplifier formed around Op Amp U47. The output voltage from U47

is scaled suitably for measurement by the MCU Analog to Digital converter and is

enabled onto the measurement bus for that purpose via an electronic switch formed

by Q 108 and Q 109. In this way the MCU can determine the current in any of the

"I" circled points (e.g. 490A, 482A) networked to the microprocessor interface 461

at any moment in time (see Figs. 4B and 4C).

Voltage measurements (e.g. 490, 482) are made similarly by appropriate

scaling by resistive voltage dividers and electronic switch multiplexing onto an

ADC input channel of the MCU representing the interface 460 again in Figs 4B and 4C.

Temperature measurements (e.g. 490E, 482E) are made similarly by using

NTC thermistor devices in a voltage division network such that the voltage

measured by the MCU via another multiplexed ADC input channel represented by

interface 462 in Figs. 4B and 4C is proportional to the thermistor resistance which

in turn is non-linearly indicative of the thermistor's temperature.

Exemplary modes of switch control are disclosed herein. The many system

switches such as those depicted in Figs. 4, 4A, 4B, 4C, and 5 are controlled via

digital signals developed in the serial to parallel data conversion circuits at Figs.

47-50. Using a few interface signals, the MCU can serially program these daisy

chained serial to parallel conversion circuits and cause their many parallel outputs

to update to the desired control states (on or off, controlling whether corresponding

switches are open or closed).

Fig. 4C is a schematic 400C illustrating the microprocessor 495, its power

supply (voltage regulator) 497A and interfaces. The voltage regulator 497A may

be a 3.3 VDC regulator from National Semiconductor. The voltage regulator

outputs 3.3 VDC to terminals represented by reference numeral 501 in Fig. 5, the

battery interface circuit. The alternating current to direct current converter 403, the

first direct current input bus 430A, the second direct current input bus 439A, the

third direct current input bus 450B and an independent replaceable battery 497 are supplied in parallel to the voltage regulator to ensure power 497 A and control of

the power supply device. Voltage 496 of the battery is monitored by the

microprocessor to inform the user that battery 497 is low. Also schematically

indicated are interfaces 464, 465, 466, and 467 with a plurality of back-up energy

subsystems which may be a rack of rechargeable batteries. Voltage 460, current

461 and temperatures from the individual components mounted on the mother

board are indicated as well as a time base for clocking measurements, controlling

the switching and communicating internally and externally. The interface 495X

converter output voltage control interface which allows the microprocessor to

control and adjust the voltage (and thereby current) of each DC/DC converter in

the system is also depicted.

Still referring to Fig. 4C, other inputs to the microprocessor includes a door

open sensor 491, power supply ambient temperature 492, status LEDs 494, fan

interface 498, serial interface 499 and Ethernet interface 499A. The serial interface

may be used in conjunction with a service computer to interface to all status and

control features of the intelligent power supply. Likewise, the Ethernet interface

may be used for local interface and inquiries or may be used to connect the

intelligent power supply to a network whereby its management functions may be

implemented from client computers anywhere in the world having network access.

Switches 493 indicate globally the control of all switches on the motherboard for directing and routing power, and all switches for all of the battery interface

circuits. There may also be pushbutton or other user input switches which are

sensed and upon actuation responded to by the power supply controller.

Fig. 8 is an illustration 800 of the processing steps used in a configurable

microprocessor control algorithm including: measuring voltages and currents of I

inputs, Q outputs, M buses, and K back-up batteries 801; measuring temperatures

of L converters and K back-up batteries 802; analyzing measurements to determine

optimal power switching 803; changing up to S switch states and V converter

output voltages as required to optimize power distribution 804, and periodically

updating all measurements and repeating all of the steps 805.

Figs. 9 A and 9B deserve in depth study as many of the features, benefits,

and potential uses of the scalable intelligent power supply invention are depicted

therein. Scalable Intelligent Power Supply blocks are shown 90 IA through 906A,

each having a unique Internet Protocol (IP) address assigned as exemplified at

9061. The unique IP address coupled with the Ethernet interface shown at 499A

along with appropriate software contained in MCU 495 allows each power supply

to communicate in a network fashion with each other, other equipment such as IP

peripherals such as 901C, 902C, or 903C, as well as management computers and

systems such as those depicted at 905B and 906B. This communications allows

information to be exchanged pertaining to the status or operating mode of the power supplies or other equipment. For example, a status report screen is depicted

schematically at network management computer 905B with related close up view

in 905H. 905H depicts a report originating from power supply 902A having IP

address 192.300.282.3. It can be seen that the status information includes details

pertaining to the voltages, currents, temperatures, and utilizations as applicable for

each input, converter, output, or battery within said power supply. That fact that

this power supply is operating on behalf of seismometer 3 as well as its location in

coordinates of latitude and longitude is also reported. This information is

beneficial to efficient management of the overall system as well as each particular

node. Other computers including the management computer at 906B and ad hoc

computers such as laptops in the field can also access this information.

Appropriate security mechanisms including information encryption and password

protection are envisioned as an integral part of the intelligent power supply system.

Several power supply use scenarios are depicted in Figs. 9A and 9B.

Scenario 1 at 901 depicts a power supply interfaced to a wireless router 90 IB and a

video camera 901C capable of transmitting video over Internet Protocol (VOIP).

The interfaces include a power interface 90 IF to the VOIP camera and both a

power 90 IF and an Ethernet interface 90 IG to the wireless router whereby its

Internet Address 9011 renders it reachable from anywhere on the Wide Area

Network (WAN) 908. The power supply is also interfaced to a street light 90 ID whereby it receives input power via interface 90 IE. The specification for the

scenario contained in descriptive block 901 indicate that the combined load

requirements for the wireless router and the VOIP camera add up to 55 Watts. The

output power type might be AC or DC voltages of appropriate levels depending

upon the requirements of the load devices. The scenario also specifies that input

power from street light 90 ID will be intermittent, i.e., switched on 8 hours and off

16 hours of each day. The power supply will therefore power the camera and

router from battery backup power for 16 hours while the street light power is

disabled (presumably during daylight hours) and will power the camera and router

loads as well as recharge the backup batteries for 8 hours while the street light

power is enabled. Should power fail unexpectedly during any interval, the power

supply will switch instantly to backup battery power so that operation of the loads

goes without interruption until input power is re-established. At all times, the

power supply will measure and estimate the amount of backup energy available

and compare this to the amount it knows to be required for operation to proceed

without interruption in the normal course of power cycling (8 hours on, 16 hours

off). It will be an important feature of the power supply system to be able to

predict energy deficiencies and subsequent power inadequacies and report same as

an information or alarm event to its network management entities well in advance

of such an event occurring. This report coupled with the capability of hot- swappable battery packs will allow maintenance personnel to visit the location in

advance of power running out and swap an adequate complement of worn batteries

for freshly charged ones to preclude the power failure.

Often peripherals such as the VOIP camera 901C involved in outdoor

deployments such as the street light scenario 901 will require ancillary heating

under cold environmental conditions in order to maintain correct operation. This

requirement is conventionally addressed with the addition of a heater device which

would also be powered by the power supply. This increases the power level and

backup energy required in the power supply accordingly, an appropriate heater

costing an additional 20 to 30 Watts by way of example. The opportunity arises,

with the intelligent power supply, to accomplish the requirement for ancillary heat

more efficiently. In particular, heat is generated inside the power supply as a result

of operation of voltage conversion units, charging of batteries, and power

dissipation in the electronic and electrical components of the power supply system

in general. If the power supply is connected via a duct or conduit such as that

schematically depicted by 901 J, air warmed within the power supply by

aforementioned phenomenon may be conveyed to the peripheral device requiring

ancillary heat. The ducting may be accomplished coaxially in the conduit already

positioned to convey the power cables or may occur via a separate conduit placed

expressly for the heating purposes. A fan inside the power supply, controlled by MCU 495, may be used to produce the desired air flow. The power supply may

control the amount of warm air, if any, based upon its measurement of external

temperature, its measurement of its internal air temperature, and communications

of information via its Ethernet connection with either the peripheral requiring heat

and/or its network management systems.

Scenario 2 at 902 depicts what might be instrumentation (seismometer

902C) deployed in a sunny, remote location such as the American southwest

desert. In this case power supply 902A powers the seismometer 902C as well as a

wireless network access device 902B. Power will be available to the power supply

via solar panel 902D, ordinarily over the course of 12 hours of daylight only.

During the dark periods the power supply must operate from its backup energy

sources. Cloudy days may occur when the "dark period" is extended from 12 to

perhaps 48 or more hours. Therefore, a typical deployment may utilize additional

backup energy frames such as those depicted in FIG IN to achieve the requisite

backup energy reservoir needed for prolonged, input-power-deprived operation.

Scenario 903 depicts a mobile, vehicle born application wherein power

supply 903 A derives input power from vehicle 903D when available, charging its

backup energy sources and powering its loads including network access device

903B and Voice over IP telephone 903C. The power supply may be programmed

to be cognizant of the state of the vehicle power system. The MCU 495 may infer from voltage measurements of the DC input coming from the vehicle whether or

not the vehicle is running and actively charging its own battery. In the case where

the vehicle is running, its power may be the preferred source. In the case where the

vehicle is not running, it may be preferred to power the loads from the backup

energy sources within the power supply thus preserving the vehicle battery

maximally. It may also be possible to remove (disconnect) from the vehicle

altogether and transport the power supply along with it wireless router and

telephone to a different location, perhaps another vehicle or outpost having a

different power source available. It may then be possible to reconnect the power

supply to a new power source when available and re-charge any backup energy

that was used in the transition between power sources all the while operating the

network interfaces and telephone (or other peripherals) without interruption.

Scenarios 904, 905, and 906 depict power supply applications wherein input

power is provided by a dedicated, full time AC outlet. The only interruptions

expected are those interruptions that occur on occasion in the utility grid (black out

or brown out events). These interruptions may be infrequent and of typically short

duration. Therefore, it is possible that the backup energy required in these power

supplies 904A, 905A, and 906A may be substantially less than that required in the

previously described scenarios. The advantage of the scalable power supply

architecture would then allow few backup energy packs to be populated (a partial rack full) and therefore allow a lower cost for the required system. Alternatively,

one or more of the fixed computers or network interfaces may desirably have

extended backup time to cover an extended power outage. The precise number of

energy packs and/or the desired number of frames of power packs may be applied

to each node as desired or required on a node-by-node energy/backup time

requirement basis. Finally, it may be possible that power outages may exceed the

interval for which backup power has been designed. The power supply has the

advantages of being able to accurately predict the amount of backup power

remaining, communicate anticipated backup energy deficits well in advance via its

network interface, and remain functional for additional extended periods by the

mechanism of hot swapping energy packs via maintenance intervention.

Figure 10 illustrates exemplary power supply generation circuits wherein

reference numeral 1001 indicates a negative 3.3V supply and reference numeral

1002 indicates a positive 6.6V supply.

Figure 11 illustrates exemplary microprocessor-controlled battery interface

circuits, detailed example, (1 of 20). Reference numeral 1101 is the discharge

control switch circuitry, as described in connection with Fig. 5 above. Charge

control switch circuit 1102 is shown in exemplary fashion and has been described

in connection with Fig. 5 above. Battery monitor bus multiplex circuit 1 103 has

been described above in connection with Fig. 5. And, battery information bus switch circuit 1104 has been described above as well in connection with Fig. 5.

Connector 1105, by which battery bus and switch control signals are connected

with other system elements including the microprocessor and power conversion

units, is illustrated in Fig. 11. Figures 12 through 30, are exemplary of battery

interface circuits like the one just described in connection with Fig. 11 and Fig. 5.

Reference numerals 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100,

2200, 2300, 2400, 2500, 2600, 2700, 2800, 2900 and 3000, illustrate the nineteen

additional microprocessor-controlled battery interface circuits. Any number of

battery interface circuits may be employed.

The circuitry and control methodology described herein is equally applicable

to use of modular energy supply systems in automobiles. For instance, the control

methodology described herein may be used in connection with Lithium ion

batteries used in an automobile. In this way, the batteries may be removed from

the automobile and recharged at a service station and then replaced into the vehicle

fully charged. The batteries may be separately removed from the automobile or

they may be removed in groups. The invention as taught and described herein

enable the evaluation of individual batteries and the evaluation of the energy

remaining in the batteries at the time they are swapped out (exchanged) for fully

charged batteries. In this way a motorist can effectively refuel his or her vehicle

and proceed on his or her way without worrying about stopping to charge the batteries which is time consuming as the recharge time for Lithium ion batteries is

considerable. Having the ability to quickly swap the batteries in a Lithium ion car

enables the driver to get credit for the energy in his "gas" tank. In reality the

teachings of the instant invention enable the driver to effectively have an "energy

tank" as compared to a "gas tank."

Fig. 31 illustrates 3100 exemplary AC input and AC/DC converter circuits

which are described elsewhere hereinabove in connection with Figs. 4, 4A, 4B, 4C

and 5. Reference numeral 3101 indicates input terminals for AC line, neutral, and

ground. Reference numeral 3102 indicates an AC input fuse which protects

converter 406. Reference numeral 3103 is an AC input transient voltage

suppression circuit protecting converter 406. Reference numeral 3104 is an

indication of an AC detect circuit, as described elsewhere referring to Fig. 4,

reference numerals 404, 405. Reference numeral 3105 indicates in an exemplary

fashion AC/DC converter, as described elsewhere referring to Fig. 4, reference

numeral 406. Reference numeral 3106 is exemplary of AC/DC temperature

sensing circuit, as described elsewhere referring to Fig. 4, reference numeral 412E.

Reference numeral 3107 indicates AC/DC converter DC output voltage selective

coupling as described elsewhere referring to Fig. 4 (reference numerals 406A and

412).

Fig. 32 illustrates 3200 exemplary AC/DC converter DC output voltage bus connection switches. Selective coupling circuits 3201 are illustrated for AC/DC to

DC INT BUS, as described elsewhere referring to Fig. 4 (reference numerals 406A,

407, 423, and 412B). Selective coupling circuits 3202 for coupling the AC/DC to

SECOND DC BUS as set forth and previously described in connection with Fig. 4

(406A, 408, 410, and 412A). And, selective coupling circuits 3203 for coupling

the AC/DC to THIRD DC BUS, as described elsewhere referring to Fig. 4

(reference numerals 406A, 409, 411, and 412C).

Fig. 33 illustrates 3300 First DC input circuits wherein reference numeral

3301 indicates DC input terminals for positive, negative, and ground and reference

numeral 3302 DC indicates an input fuse. DC input transient voltage suppression

circuit 3303 is illustrated as an MOV. DC input voltage monitoring selective

coupling circuit 3304 is illustrated and was described elsewhere referring to Fig.

4 A (reference numeral 438).

Fig. 34 illustrates 3400 the First DC input bus connections switches in

exemplary fashion and as described elsewhere referring to Fig. 4A. Selective

coupling circuits 3401 for coupling first DC input to second DC bus (Fig. 4A,

reference numerals 430A, 432A, 436, 412A) are illustrated in Fig. 34 as are the

selective coupling circuits 3402 for coupling the first DC input to third DC bus

(Fig. 4A, reference numerals 430A, 433, 437, 412C). Fig. 34 also depicts selective

coupling circuits 3403 for the first DC input to DC INT bus as described above in connection with Fig. 4A, reference numerals 430A, 431, 434, 412B.

Selective coupling circuits 3404 for coupling the first DC input to the first

DC bus are illustrated in Fig. 34 and also as described above in connection with

Fig. 4A, reference numerals 430A, 432, 435, 412J.

Fig. 35 illustrates 3500 the Second DC input circuits wherein reference

numeral 3501 DC indicates the input terminals for positive, negative, and ground

and reference numeral 3502 indicates the DC input fuse. Reference numeral 3503

indicates the DC input transient voltage suppression circuit (MOV) and reference

numeral 3504 illustrates the DC input voltage monitoring selective coupling circuit

as described above referring to Fig. 4 A, reference numeral 448.

Fig. 36 illustrates 3600 exemplary Second DC input bus connection

switches, as described above referring to Fig. 4A. Selective coupling circuits 3601

for coupling the second DC input to second DC bus are illustrated in Fig. 36 and

have been described previously in Fig. 4A, reference numerals 439A, 442, 446,

412A. Selective coupling circuits 3602 for coupling second DC input to third DC

bus are illustrated in Fig. 36 in exemplary fashion and are discussed above in

connection with Fig. 4A, reference numerals 439A, 443, 447, 412C. Selective

coupling circuits 3603 for coupling the second DC input to DC INT bus are

illustrated by way of example in Fig. 36 and were discussed above in connection

with Fig. 4A, reference numerals 439A, 440, 444, 412B. And, selective coupling circuits 3604 for coupling the second DC input to the first DC bus are illustrated by

way of example in Fig. 36 and are discussed above in connection with Fig. 4 A,

reference numerals 439 A, 441, 445, 412J.

Fig. 37 illustrates 3700 the Third DC input battery pack array circuits

wherein reference numeral 3701 indicates DC input fuse and reference numeral

3702 indicates DC input transient voltage suppression circuit as described above as

an MOV. DC input voltage monitoring selective coupling circuit 3703 is also

depicted in Fig. 37 and is described elsewhere described elsewhere in Fig. 4A,

reference numeral 459.

Fig. 38 illustrates 3800 the Third DC input bus connections switches

described above in connection with Fig. 4A wherein selective coupling circuits

3801 couple the third DC input with the second DC bus, Fig. 4A, reference

numerals 450B, 453, 457, 412A. Also shown in Fig. 38 are the selective coupling

circuits 3802 for coupling the third DC input to third DC bus as described above in

connection with Fig. 4A, reference numerals 450B, 454, 458, 412C. Selective

coupling circuits 3803 for coupling the third DC input to DC INT bus as described

above in connection with Fig. 4A, reference numerals 450B, 451, 455, 412B and

selective coupling circuits 3804 for coupling the third DC input to first DC bus are

shown in Fig. 38 and were previously described above in connection with Fig. 4A,

reference numerals 450B, 452, 456, 412J. Fig. 39 illustrates 3900 the First DC/DC converter circuits 3901 described

above in Fig. 4B (reference numeral 475) wherein First DC/DC converter

temperature measuring circuit 3902 was described in Fig. 4B in connection with

reference numeral 482E. Alternative first DC/DC converter 3903 having a detailed

pin assignment differing from 3901 is also illustrated in Fig. 39. DC/DC converter

voltage monitoring selective coupling circuit 3904 described in connection with

Fig. 4B, reference numeral 482 and is illustrated in Fig. 39.

Fig. 40 illustrates 4000 the First DC/DC converter bus connections switches

described in connection with Fig. 4B wherein selective coupling circuits 4001 for

coupling the first DC/DC converter to DC INT bus were described in connection

with reference numerals 475A, 477, 480, 412B. Selective coupling circuits 4002

for coupling the first DC/DC converter to third DC bus are illustrated in Fig. 40

and were described above in connection with Fig. 4B, and in particular with

reference numerals 475 A, 478, 480A, 412C. Selective coupling circuits for 4003

for coupling the first DC/DC converter to the DC charge bus are illustrated in Fig.

40 and were described above in connection with Fig. 4B, reference numerals 475A,

479, 481, 489A.

Fig. 41 illustrates 4100 the Second DC/DC converter circuits 4101 described

elsewhere referring to Fig. 4B (reference numeral 483) and the Second DC/DC

converter temperature measuring circuit 4102 as described elsewhere referring to Fig. 4B ( reference numeral 490E). Alternative second DC/DC converter 4103

having a detailed pin assignment differing from 4101 is illustrated in Fig. 41 as

well. DC/DC converter voltage monitoring selective coupling circuit 4104 as

described elsewhere referring to Fig. 4B (reference numeral 490) is also illustrated

in Fig. 41.

Fig. 42 illustrates 4200 in exemplary fashion the Second DC/DC converter

bus connections switches described in Fig. 4B wherein the selective coupling

circuits 4201 for coupling the second DC/DC converter to DC INT bus. See the

discussion of Fig. 4B as it pertains to reference numerals 483A, 484, 487, 412B.

Selective coupling circuits 4202 for coupling the second C/DC converter to third

DC bus as described in above in connection Fig. 4B and reference numerals 483A,

485, 488, 412C are shown in Fig. 42. Also, selective coupling circuits 4203 for

coupling the second DC/DC converter to DC charge bus are shown in Fig. 42 and

were discussed above in connection with Fig. 4B, reference numerals 483A, 486,

489, 489A.

Fig. 43 illustrates 4300 the DC/AC inverter circuits wherein the DC/AC

inverter input power switch 4301 as described elsewhere referring to Fig. 4,

reference numeral 413, and DC/AC inverter 4302 as described in Fig. 4, reference

numeral 414 are shown. DC/AC inverter temperature measuring circuit 4303 is

also illustrated in Fig. 43 and previously described referring to Fig. 4, reference numeral 416B.

Still referring to Fig. 43, DC/AC inverter output terminals 4303 for line,

neutral, and ground are shown as is the DC/AC inverter output fuse 4305. DC/AC

inverter output transient voltage suppression circuit 4306 is illustrated in Fig. 43 as

an MOV and was described previously. DC/AC inverter AC detect circuit 4307 is

illustrated in Fig. 43 and was described above in regard to Fig. 4, reference

numeral 415 and 416.

Fig. 44 illustrates 4400 the First DC output circuits wherein the First DC

output switch 4401 was described elsewhere referring to Fig. 4, reference numeral

425. First DC output terminals 4402 for positive, neutral, and ground are shown in

Fig. 44 as is the First DC output fuse 4403. First DC output transient voltage

suppression circuit 4404 is an MOV as was previously described above. First DC

output voltage monitoring selective coupling circuit 4405 is illustrated in Fig. 4

and described above in connection with Fig. 4, reference numeral 420. DC/AC

inverter input voltage monitoring selective coupling circuit 4406 is also illustrated

in Fig. 44 and was described hereinabove in connection with Fig. 4, reference

numeral 419.

Fig. 45 illustrates 4500 the Third DC bus and fourth DC/DC converter

circuits wherein the Third DC bus voltage monitoring selective coupling circuit

4501 as described elsewhere referring to Fig. 4A, reference numeral 470A. Fourth DC/DC converter input voltage switch 4502 is disclosed in Fig. 45 as described

elsewhere referring to Fig. 4A, reference numeral 474. Fourth DC/DC converter

output voltage monitoring selective coupling circuit 4503 as described elsewhere

referring to Fig. 4A, reference numeral 473A.

Figure 46 illustrates 4600 the fourth, fifth, and sixth DC outputs and fourth

DC/DC converter circuits wherein the Fourth DC output terminals for positive,

neutral, and ground 4601 and the Fourth DC output fuse 4602 are illustrated. The

Fourth DC output transient voltage suppression circuit 4603 is an MOV and the

Fifth DC output terminals 4604 for positive, neutral, and ground are also illustrated

in Fig. 46. Fifth DC output fuse 4605 and the Fifth DC output transient voltage

suppression circuit 4606 which is an MOV are illustrated in Fig. 46. Fourth

DC/DC converter 4607 and Sixth DC output 4608 as described elsewhere referring

to Fig. 4A , reference numeral 473 and 472, respectively, are also illustrated in Fig.

46. And, Fourth DC/DC converter temperature measuring circuit 4609 is illustrated

in Fig. 46 and was illustrated previously in Fig. 4A as reference numeral 473E.

Fig. 47 illustrates 4700 serial to parallel circuits to implement serial

microprocessor control instructions into parallel control signals wherein power

supply decoupling capacitors 4701 for the respective integrated circuits are shown.

Serial to parallel converters 4702 are also illustrated in Fig. 47.

Figs. 48-50, reference numerals 4800, 4900, 5000, illustrate additional serial to parallel circuits implementing the microprocessor control signals.

Fig. 51 illustrates 5100 Microcontroller interface circuits wherein the

temperature measuring circuit interface 5101 to the microcontroller is shown and

was described elsewhere referring to Fig. 4C, reference numeral 462. Reference

numeral 5102 indicates the battery monitor bus circuit interface to microcontroller

as described elsewhere referring to Fig. 5, reference numeral 495A. Reference

numeral 5103 indicates a voltage monitor circuit interface to the microcontroller as

described elsewhere referring to Fig. 4C, reference numeral 460. The current

monitor circuit interface 5104 to the microcontroller is shown in Fig. 51 and is

described elsewhere referring to Fig. 4C, reference numeral 461. And, reference

numeral 5105 indicates the serial interface to microcontroller as described

elsewhere referring to Fig. 4C, reference numeral 499.

Fig. 52 illustrates 5200 the Microcontroller and support circuits. Reference

numeral 5201 indicates the voltage regulator and power supply for the

microcontroller as described elsewhere referring to Fig. 4C, reference numerals

403, 430A, 439A, 450B, 497A and 497. The Microcontroller unit is indicated as

reference numeral 5202.

Fig. 53 illustrates 5300 the Microcontroller interface circuits wherein door

switch interface circuit 5301 to the microcontroller is shown and was described

elsewhere referring to Fig. 4C, reference numeral 491. Reference numeral 5302 represents a light emitting diode interface circuit to the microcontroller as was

described elsewhere referring to Fig. 4C, reference numeral 494. Dual cooling fan

control circuits interface 5303, 5304 to the microcontroller are shown and were

described elsewhere referring to Fig. 4C (498).

Fig. 54 illustrates 5400 current monitoring circuits in an exemplary fashion.

Reference numeral 5401 indicates the current monitor interface for third DC input

battery pack array as described elsewhere referring to Fig. 4A, reference numeral

495A. Reference numeral 5402 indicates the current monitor interface for the first

DC input as described elsewhere referring to Fig.4A, reference numeral 438 A.

Current monitor interface 5403 for second DC input is also shown in Fig. 54 and

was previously described above referring to Fig. 4A, reference numeral 448A.

Current monitor interface 5404 for AC/DC converter output is indicated in Fig. 54

as well and was described elsewhere referring to Fig. 4, reference numeral 412D.

Fig. 55 illustrates 5500 the current monitoring circuits wherein the current

monitor interface for the first DC/DC converter 5501 is shown and was described

elsewhere referring to Fig. 4B, reference numeral 482A. Reference numeral 5502

indicates the current monitor interface for the second DC/DC converter and was

described elsewhere herein in regard to Fig. 4B, reference numeral 490A.

Reference numeral 5503 indicates current monitor interface for DC/AC inverter

input as was described elsewhere referring to Fig. 4, reference numeral 416A. Fig. 56 illustrates 5600 a current monitoring circuits wherein reference

numeral 5601 indicates the current monitor interface for first DC output as

described elsewhere referring to Fig. 4, reference numeral 420A. Current monitor

interface 5602 for the second DC output as described elsewhere referring to Fig. 4

Reference numeral 5603 indicates the current monitor interface for third DC/DC

converter as described elsewhere referring to Fig. 4, reference numeral 424A and

reference numeral 5604 indicates the current monitor interface for fourth DC/DC

converter as described elsewhere referring to Fig. 4A, reference numeral 473B.

Fig. 57 illustrates 5700 the DC/DC converter voltage programming circuits

wherein reference numeral 5701 indicates the voltage programming circuit for the

first DC/DC converter as described elsewhere referring to Fig. 4B, reference

numeral 495X. Voltage programming circuit 5702 for the third DC/DC converter is

illustrated in Fig. 57 and was described elsewhere referring to Fig. 4B, reference

numeral 495X. Reference numeral 5703 is the voltage programming circuit for the

second DC/DC converter as described elsewhere referring to Fig. 4B, reference

numeral 495X. Reference numeral 5704 indicates the voltage programming circuit

for the fourth DC/DC converter as described elsewhere referring to Fig. 4B,

reference numeral 495X. And, reference numeral 5705 indicates the digital to

analog converter used to generate voltage programming levels.

Fig. 58 illustrates 5800 the second and third DC outputs and third DC/DC converter circuits in an exemplary fashion wherein the Third DC/DC converter

input voltage switch 5801 is shown and was described elsewhere referring to Fig.

4, reference numeral 425A. The Third DC/DC converter voltage monitoring

selective coupling circuit 5802 is also shown in Fig. 58 and was described

elsewhere referring to Fig. 4, reference numeral 424. Third DC/DC converter 5803

is shown as well in Fig. 58 and was described elsewhere referring to Fig. 4,

reference numeral 427. Second DC output terminals 5804 are indicated as well for

positive, neutral, and ground (426). Also shown is the Second DC output fuse 5805

and the Second DC output transient voltage suppression circuit 5806 which is an

(MOV). Third DC output 5807 (Fig. 4, reference numeral 428). Third DC/DC

converter temperature measuring circuit 5808 is also shown in Fig. 58 and was

described elsewhere referring to Fig. 4, reference numeral 424B.

Fig. 59A is schematic 5900A illustrating twenty battery packs 5901

interconnected in parallel to a common battery bus 5903 leading to either a DC-AC

inverter 5915 of fig. 59 or to a DC-DC converter 5906 of Fig. 59B which

subsequently is interconnected to a DC-AC inverter 5916.

Fig. 59B and 59C are schematics 5900B and 5900C illustrating: the

interconnection of the battery array 5901with a DC-DC converter 5906 which is

interconnected via cable assembly 5907 with a diode 5912 which in turn is

interconnected with a bus leading to a DC-AC inverter; and, the interconnection via cable assembly to connector 5909 to connector 5910 of an AC-DC converter

5908 which in turn is interconnected with a diode which in turn is interconnected

with a bus leading to the D C-AC inverter 5915.

Fig. 59D illustrates 5900D the power supply with the battery rack 5924 is

removed therefrom and the electronics 5921 (AC/DC converter, diodes etc.)

mounted to the rear wall 5922 of the housing or frame 5918; also shown are two

removable Lithium Ion rechargeable battery packs 5926. Electronics 5920

(DC/AC inverters) are also mounted to the rear wall on the ceiling of the power

supply . A grouping of wires (harness) 5925 is also illustrated.

Fig. 59E is a view 5900E similar to Fig. 59D illustrating the power supply

with the battery rack removed therefrom and further illustrating the power

receptacles 5923, the AC input on the right hand side thereof, and the on-off

switch. Fig. 59F is a view similar to Figs. 59D and 59E with the battery rack 5924

mounted in the housing or frame.

Fig. 59G is a view 5900G similar to the immediately preceding Figs. 59D-

59F inclusive with the battery rack populated with removable cartridge type

Lithium Ion batteries 5926. Also shown is box 5927 with electronic

communications equipment therein representing a load device being powered by

the power supply.

Fig. 59H is a view 5900H similar to the immediately preceding Figs. 59D- 59G inclusive with the door of the power supply closed and illustrating the power

supply interconnected with a load 5927 such as wireless radio equipment.

Figs. 59A-59H illustrate the example of a power supply having a DC input

from a plurality of removable, hot-swappable, and interchangeable power batteries

5901 which provide power on a common battery bus 5903 to a DC-AC inverter

5915. Alternatively, and additionally, AC power may be supplied to the power

supply through an AC-DC converter 5908 which is then converted back to AC by

inverter 5915 outputting to 5916 for purposes of reliability and for the purpose of

seamless transition (on-line topology). The output of the AC to DC converter is

arranged in a diode oring fashion together with the output from the common

battery bus 5903 via diodes 5912. The diode oring selects of the higher voltage in

converting from DC to AC power. Further, the common battery bus voltage may

be converted by a DC to DC converter 5906 intermediate the common battery bus

5903 and the diode 5912 in series leading to the junction with the output of the

AC-DC converter. Use of the DC to DC converter is optional depending on the

voltage of the batteries used in the power supply and thus enables use of

rechargeable batteries which have a relatively low output voltage. In the example

of Figs. 59A-59G a power supply is provided which does not require a

microprocessor to manage its operations. Rather, this example provides a seamless

transition from an AC power input to a DC power input with hot-swappablility of the batteries. The batteries may be cordless tool batteries capable of dual use.

Further, the batteries may be Li-Ion or any of the types referred to herein.

Figure 60 is an illustration of the conceptual management hierarchy of the

power supply system. By virtue of this hierarchical arrangement the network

management user may access the status and control parameters for all subsystems

under a particular gateway. This is described elsewhere referring to Figs. 9A and

9B. In particular, in Fig. 9B, information is shown for batteries (energy

subsystems and energy modules of figure 60), inputs, converters, and outputs

(power conversion and control units of figure 60), and SIPS IP ADDR (gateway of

Fig. 60).

Reference numeral 6001 is the Gateway which interconnects the power

supply system below to a network (local or wide area). All aspects of the

underlying power supply status and operation may be monitored and controlled by

the user via this network. Reference numeral 6002 is used to indicate in exemplary

fashion that up to P (where P is a positive integer) power conversion and control

units may be connected for management purposes to each gateway. Similarly,

reference numeral 6003 indicates in exemplary fashion that up to S energy

subsystems (where S is a positive integer) may be connected for management

purposes to each power conversion and control unit. Reference numerals 6004

indicates that up to M energy modules (where M is a positive integer) may be connected for management purposes to each energy subsystem. Energy modules

include but are not limited to lithium ion based batteries.

Figure 61 A is an exemplary depiction of the physical arrangement of a

power supply system. By virtue of this hierarchical arrangement the power supply

user may configure and control a power supply systems under a particular gateway.

In particular Fig. 61 shows an example of a physical arrangement of a gateway unit

6101 connected to at least one power conversion and control unit 6102 which in

turn is connected to at least one energy subsystem 6103 which in turn is connected

to at least one energy module 6104. In particular, in Fig. 61, the power conversion

and control unit is depicted as physically separate from the energy subsystems.

Further the energy subsystems are shown to house the energy modules. As long as

at least one energy subsystem having at least one energy module is connected to a

power conversion and control unit, the power conversion and control unit may

continue to operate provide power and management control to the user.

Figure 61B is an alternative depiction of a physical arrangement of a power

supply system. In this case the gateway, power conversion and control unit, energy

subsystem, and energy modules are co-housed in a common enclosure 6105.

Electrical interconnections are otherwise equivalent with the arrangement of figure

6 IA. Additionally, an energy subsystem 6103 (separately housed) is shown

connected to the power conversion and control unit housed within 6105. Additional external energy subsystems may be connected at the same time. As

mentioned earlier, as long as at least one energy subsystem (co-housed or

separately housed) having at least one energy module is connected to a power

conversion and control unit, said power conversion and control unit may continue

to operate provide power and management control to the user.

Just as the instant invention contemplates that various functional units may

be packaged separately or coincidently, so does the invention also contemplate that

control may be implemented in a single microcontroller or distributed across

multiple intercommunicating microcontrollers. In one example, each gateway may

have a microcontroller, each power conversion and control unit may have a

microcontroller, each energy subsystem may have a microcontroller, each of the

microcontrollers intercommunicating with others to which it is connected for that

purpose. In another example, a single microcontroller may control all units

including gateway, multiple PCCU's, etc.

The battery power supply circuitry and control methodology described

herein is equally applicable to modular energy systems for battery electric vehicles

of types including but not limited to automobiles, ultra light weight automobiles,

scooters, motorized bicycles and tricycles, buses, trucks, military vehicles, boats,

etc. For instance, the control methodology described herein may be used in

connection with lithium ion batteries in an electric automobile. Referring to Fig. 62, a power supply 6201 using quick disconnect cartridge type batteries 6202

within an automobile 6203 connects any combination of batteries via switches 508

to a battery bus 450A which in turn connects battery power to the vehicle electric

motor system to power motors 6204. The power supply 6201 can also receive

power regenerated by braking during vehicle operation from the vehicle motor

control system and can connect said received power to the charge bus 489A which

in turn routes power via switches 512 to batteries for re-charging. At an

appropriately configured service station 6205, the automobile's partially

discharged batteries 6202 may be quickly removed and replaced with fully charged

batteries 6206 from the service station. The batteries 6202 may be energy modules

or hand sized battery packs such as 6104 or they may be energy subsystems

including multiple energy modules such as 6103. Removal and replacement at the

service station may proceed at the module 6104 or subsystem 6103 level. Repair

or replacement of failed modules is still possible at the module 6104 level.

Removed battery modules or subsystems may be recharged outside of the

vehicle by a service station power supply using the control mechanisms described

in conjunction with the charge bus 489A from figures 4 and 5 and switches 512.

The invention as taught and described herein enables various evaluations of

individual batteries including the estimation of the energy remaining in the

batteries at any time including the time at which they are being removed from a vehicle. This evaluation is facilitated using the battery monitor bus 495A and the

battery info bus 495B along with the calculations performed by microcontroller

495. The condition of individual batteries is also estimated including remaining

cycle life (how many more time a battery may be charged and discharged before

end of life), present capacity (how much energy the battery can hold in its current

state of health), internal resistance or impedance, and maximum current or power

capability. Batteries may be likewise evaluated at the time they are being installed

into a vehicle. Either the vehicle born system or the service station system or both

may perform these evaluations. In this way the battery power supply vehicle

system can calculate a "refueling" fee to be paid by the motorist which corresponds

appropriately to the net gain in energy (i.e. energy of the replacement batteries less

energy of removed batteries) as well as any fee components, surcharges, or credits

corresponding to the differential life or other conditions of the replacement versus

the removed batteries. As mentioned above, batteries removed from vehicles are

re-charged external to the vehicle at the service station after the motorist continues

on his way with his charge laden replacement batteries. In this way the motorist

can effectively "refuel" his or her vehicle and proceed on his or her way quickly, in

a time frame comparable to the gasoline refueling process, for a fair fee based on

the actual energy gained in refueling, without worrying about the significant

recharge time for lithium ion or other battery types that would otherwise require inconvenient delays if the batteries needed to be recharged in place aboard the

vehicle.

Since many batteries are processed (evaluated, recharged, and maintained)

external to vehicles at appropriate service stations, the station can be configured to

optimize the recharging and other handling procedures associated with its array of

batteries. For example, batteries can be charged at a moderate rate that is

optimized for maximizing battery life, or at a rate or time of day that is optimal for

minimizing recharge energy cost, or other cost factors. For example, electrical

demand costs can be controlled by controlling in turn which batteries are connected

to the charge bus at any given time. In other words, batteries may be charged at

night when the availability of power is high and the demand costs are low. In this

way, refueling of an electric vehicle using quick disconnect batteries or groups of

batteries is most cost effective. Additionally, use of the electric utility grid to

charge batteries at a service station for insertion into a vehicle to refuel it

effectively enables energy to be supplied to a vehicle through batteries charged

with power made from coal, natural gas, atomic energy, wind or solar panels. This

optimization is not as feasible if the batteries remain in the vehicle to be recharged

while the motorist waits. Under such conditions the motorist's convenience

becomes the limiting factor. It is also an aspect of the present invention that the batteries may be

recharged while remaining in the vehicle such that, when recharge time is not a

limiting factor such as when the vehicle is not in use, and when a satisfactory

electrical power source is available such as an electric utility outlet, "refueling" can

occur without the need of a battery exchange at a battery service station. The

invention disclosed herein allows the charge bus and related control and switching

mechanisms to operate to the effect of the desired recharging while the batteries

remain aboard the vehicle.

It is also an aspect of the present invention that auxiliary vehicle batteries

may be held by the motorist, either at the vehicle's home or depot site, or carried

aboard the vehicle as additional payload, said auxiliary batteries being

interchangeable with the operating batteries of the vehicle in relatively efficient

fashion so that the vehicle may be "refueled" by the motorist by exchanging spent

batteries with charged auxiliary batteries. Spent batteries may then be delivered to

a battery service station for credit, recharging, or exchanged for charged batteries,

or may be recharged external to or onboard the vehicle by the motorist himself or

other party.

The invention described herein has been set forth by way of example only.

Those skilled in the art will readily recognize that changes may be made to the invention without departing from the spirit and scope of the invention as defined

by the claims which are set forth below.

Claims

CLAIMSI claim:

1. A power supply comprising at least one removable cartridge battery pack.

2. A power supply as claimed in claim 1 further comprising a plurality of removable

cartridge battery packs.

3. A power supply as claimed in claim 2 wherein each removable cartridge

battery pack of said plurality of removable cartridge battery packs has an output voltage.

4. A power supply as claimed in claim 3 further comprising a microprocessor

wherein each removable cartridge battery pack of said plurality of removable cartridge

battery packs is controlled by said microprocessor.

5. A power supply as claimed in claim 4 wherein each removable cartridge battery pack

of said plurality of removable cartridge battery packs is selectively interconnected to a

load and is selectively disconnected from said load.

6. A power supply as claimed in claim 5 wherein said load is a sense resistor.

7. A power supply as claimed in claim 5 wherein said load is a user defined electrical

load.

8. A power supply as claimed in claim 5 wherein said load is a sense resistor in parallel

with a user defined electrical load.

9. A power supply as claimed in claim 6 wherein said microprocessor measures the

voltage across the load (Vcc, voltage closed circuit) of each removable cartridge battery

pack while said each removable cartridge battery pack is interconnected with said load.

10. A power supply as claimed in claim 7 wherein said microprocessor measures the

voltage across the load (Vcc, voltage closed circuit) of each removable cartridge battery

pack while said each removable cartridge battery pack is interconnected with said load.

11. A power supply as claimed in claim 8 wherein said microprocessor measures the

voltage across said user defined load in parallel with said sense resistor (Vcc-load-sense,

voltage closed circuit-load-sense) of each removable cartridge battery pack while said

each removable cartridge battery pack is interconnected with said loads.

12. A power supply as claimed in claim 6 wherein said microprocessor measures the

unloaded voltage (Voc, voltage open circuit) of each removable cartridge battery pack

while said each removable cartridge battery pack is disconnected from said load.

13. A power supply as claimed in claim 7 wherein said microprocessor measures the

unloaded voltage (Voc, voltage open circuit) of each removable cartridge battery pack

while said each removable cartridge battery pack is disconnected from said load.

14. A power supply as claimed in claim 8 wherein said microprocessor measures the

voltage across the user defined load (Voc, voltage open circuit) of each removable

cartridge battery pack while said each removable cartridge battery pack is disconnected

from said load.

15. A power supply comprising a plurality of removable cartridge battery packs, each of

said removable cartridge battery packs of said plurality of battery packs has a known Re

(internal resistance) and an output voltage, a microprocessor for controlling each

removable cartridge battery pack of said plurality of removable cartridge battery packs,

each of said removable cartridge battery packs of said plurality of battery packs is selectively interconnected to a user defined load, said microprocessor measures the

voltage across said user defined load (Vcc-ul, voltage closed circuit-user load) of each

removable cartridge battery pack of said plurality of removable cartridge battery packs

while said each removable cartridge battery pack is interconnected with said load, and,

said microprocessor measures the unloaded voltage (Voc, voltage open circuit) of each

removable cartridge battery pack of said plurality of removable cartridge battery packs

while said each removable cartridge battery packs is disconnected from said load, said

microprocessor determining a difference between said unloaded voltage (Voc, voltage

open circuit) and said loaded voltage (Vcc-ul, voltage closed circuit-user-load) and

dividing said difference (Voc minus Vcc-ul) by Re (internal resistance) to determine Ice

(closed circuit current).

16. A power supply comprising a plurality of removable cartridge battery packs, each of

said removable cartridge battery packs of said plurality of removable cartridge battery

packs has a known Re (internal resistance) and an output voltage, a microprocessor for

controlling each removable cartridge battery pack of said plurality of removable cartridge

battery packs, each of said removable cartridge battery packs of said plurality of battery

packs is selectively interconnected to a sense resistor, said microprocessor measures the

voltage across said sense resistor (Vcc-sr, voltage closed circuit-sense resistor) of each

removable cartridge battery pack of said plurality of removable cartridge battery packs

while said each removable cartridge battery pack is interconnected with said sense

resistor, and, said microprocessor measures the unloaded voltage (Voc, voltage open

circuit) of each removable cartridge battery pack of said plurality of removable cartridge battery packs while said each removable cartridge battery packs is disconnected from said

sense resistor, said microprocessor determining a difference between said unloaded

voltage (Voc, voltage open circuit) and said loaded voltage (Vcc-sr, voltage closed

circuit-sense resistor) and dividing said difference (Voc minus Vcc-sr) by Re (internal

resistance) to determine Ice (closed circuit current).

17. A power supply comprising a plurality of removable cartridge battery packs, each of

said removable cartridge battery packs of said plurality of battery packs has an Re

(internal resistance) and an output voltage, a microprocessor for controlling each

removable cartridge battery pack of said plurality of removable cartridge battery packs,

each of said removable cartridge battery packs of said plurality of battery packs is

selectively interconnected to a user defined load and a known sense resistor (Rsense) in

parallel with said user defined load, said microprocessor measures the voltage across said

known sense resistor in parallel with said user defined load Vcc-sr-ul (voltage closed

circuit-sense resistor-user defined load) of each removable cartridge battery pack of said

plurality of removable cartridge battery packs while said each removable cartridge battery

pack is interconnected with said user defined load and a known sense resistor (Rsense) in

parallel with said user defined load, and, said microprocessor measures the unloaded

voltage across said user defined load Vcc-ul (voltage closed circuit-user defined load) of

each removable cartridge battery pack of said plurality of removable cartridge battery

packs while said each removable cartridge battery packs is disconnected from said known

sense resistor, said microprocessor using Vcc-sr-ul, Vcc-ul, Re, and Rsense to determine Ice (closed circuit current user defined load in parallel with Rsense) and Iload (current

through user defined load).

18. A power supply as claimed in claim 15 further comprising a charging circuit and

wherein said microprocessor selectively interconnects said charging circuit with each of

said removable cartridge battery packs or said microprocessor selectively disconnects said

removable cartridge battery packs based on Ice.

19. A power supply as claimed in claim 16 further comprising a charging circuit and

wherein said microprocessor selectively interconnects said charging circuit with each of

said removable cartridge battery packs or said microprocessor selectively disconnects said

removable cartridge battery packs based on Ice.

20. A power supply as claimed in claim 17 further comprising a charging circuit and

wherein said microprocessor selectively interconnects said charging circuit with each of

said removable cartridge battery packs or said microprocessor selectively disconnects said

removable cartridge battery packs based on Ice.

21. A power supply comprising a plurality of removable cartridge battery packs, a

microprocessor, said microprocessor selectively interconnects each of said removable

cartridge battery packs to a battery information bus.

22. A power supply comprising a plurality of removable cartridge energy packs, a

microprocessor, said microprocessor selectively interconnects each of said removable

cartridge energy packs to an energy pack information bus.

23. A power supply as claimed in claim 21 wherein said removable cartridge battery

packs are selected from the group consisting of Li-Ion, Li-Ion polymer, NiMH, NiCd,

lead acid and Alkaline batteries.

24. A power supply as claimed in claim 22 wherein said removable cartridge energy

packs are selected from the group consisting of Li-Ion, Li-Ion polymer, NiMH, NiCd lead

acid and Alkaline batteries.

25. A power supply comprising a plurality of removable cartridge battery packs, a

microprocessor, a sensor in proximity to each of said removable cartridge battery packs, a

battery information bus, said microprocessor interconnecting said sensor with said battery

information bus.

26. A power supply as claimed in claim 25 wherein said sensor is a temperature sensor.

27. A power supply comprising a plurality of removable cartridge battery packs, each of

said removable cartridge battery packs is selectively interconnected to a battery bus

interconnected with a load, each of said removable cartridge battery packs is selectively

interconnected to a charge bus, and, each of said removable cartridge battery packs is

selectively interconnected to a battery monitor bus.

28. A power supply as claimed in claim 27 further comprising a microprocessor and

wherein said each of said removable cartridge battery packs are selectively interconnected

to said battery bus interconnected with said load through a PFET controlled by said

microprocessor.

no

29. A power supply as claimed in claim 27 further comprising a microprocessor and

wherein said each of said removable cartridge battery packs are selectively interconnected

to said charge bus through a PFET controlled by said microprocessor.

30. A power supply as claimed in claim 27 further comprising a microprocessor and

wherein said each of said removable cartridge battery packs are selectively interconnected

to said battery monitor bus through a PFET controlled by said microprocessor.

31. A power supply as claimed in claim 27 wherein said battery monitor bus multiplexes

voltage measurements indicative of the state of charge of each of said removable

cartridge battery packs to said microprocessor.

32. A power supply as claimed in claim 27 wherein each of said removable cartridge

battery packs is selectively interconnected to a battery information bus.

33. A power supply as claimed in claim 32 wherein said battery information bus

multiplexes voltages representative of temperature measurements indicative of the current

through each of removable cartridge battery packs.

34. A power supply as claimed in claim 27 wherein a single removable cartridge battery

pack is interconnected with said load to maximize the current through said battery

producing heat in said battery.

35. A power supply as claimed in claim 27 wherein each of said plurality of removable

cartridge battery packs is interconnected with said load.

36. A power supply comprising a microprocessor, a plurality of removable cartridge

battery packs, each of said removable cartridge battery packs is selectively interconnected

to a battery bus interconnected with a load, said microprocessor selectively i n interconnecting any combination of said plurality of removable cartridge battery packs

with said battery bus.

37. A power supply comprising a microprocessor, a plurality of removable cartridge

battery packs, each of said removable cartridge battery packs is selectively interconnected

to a battery bus interconnected with a load, said microprocessor selectively

interconnecting some of said removable cartridge battery packs with said load, and, said

microprocessor selectively interconnecting the remainder of said removable cartridge

battery packs with said charge bus.

38. A power supply comprising a microprocessor, a plurality of removable cartridge

battery packs, each of said removable cartridge battery packs is selectively interconnected

to a battery bus interconnected with a load, said microprocessor selectively

interconnecting some of said removable cartridge battery packs with said load, and, said

microprocessor selectively interconnecting the remainder of said removable cartridge

battery packs with said charge bus.

39. A power supply comprising a microprocessor, a plurality of removable cartridge

battery packs, each of said removable cartridge battery packs is selectively interconnected

to a battery bus interconnected with a load, each of said removable cartridge battery packs

is selectively interconnected to a charge bus, said microprocessor selectively

interconnecting a first portion of said plurality of removable cartridge battery packs with

said battery bus, said microprocessor selectively interconnecting a second portion of said

plurality of removable cartridge battery packs with said charge bus, said microprocessor

selectively interconnecting a third portion of said plurality of removable cartridge battery packs with both said battery bus and said charge bus, and, said microprocessor selectively

disconnecting a fourth portion of said plurality of removable cartridge packs from both

said charge bus and said battery bus.

40. A power supply comprising a microprocessor, a plurality of removable cartridge

battery packs, each of said removable cartridge battery packs is selectively connected or

disconnected with a battery bus interconnected with a load, each of said removable

cartridge battery packs is selectively connected or disconnected with a charge bus, said

microprocessor selectively connecting a first portion of said plurality of removable

cartridge battery packs with said battery bus, said microprocessor selectively connecting a

second portion of said plurality of removable cartridge battery packs with said charge bus,

said microprocessor selectively connecting a third portion of said plurality of removable

cartridge battery packs with both said battery bus and said charge bus, and, said

microprocessor selectively disconnecting a fourth portion of said plurality of removable

cartridge packs from both said charge bus and said battery bus.

41. A power supply as claimed in claim 40 wherein said first, second, third and fourth

portions of said plurality of removable cartridge battery packs may include one, more

than one, all, or none of the plurality of removable cartridge battery packs.

42. A power supply as claimed in claim 40 wherein said plurality of removable cartridge

battery packs includes batteries having different nominal voltages.

43. A power supply as claimed in claim 41 wherein said plurality of removable cartridge

battery packs includes batteries having different nominal voltages.

44. A power supply comprising a microprocessor, a plurality of removable cartridge

battery packs, each of said removable cartridge battery packs is selectively connected or

disconnected with a battery bus interconnected with a load, each of said removable

cartridge battery packs is selectively connected or disconnected with a charge bus, and

wherein said load includes a direct current to direct current step up converter outputting to

said charge bus.

45. A power supply as claimed in claim 44 wherein said charge bus is at a voltage higher

than the nominal voltage of each of said removable cartridge battery packs.

46. A power supply as claimed in claim 44 wherein a first portion of said removable

cartridge battery packs charge a second portion of said removable cartridge battery packs.

47. A power supply as claimed in claims 40 to 46 wherein said removable cartridge

battery packs are dual purpose battery packs.

48. A power supply as claimed in claims 40 to 46 wherein said removable cartridge

battery packs are dual purpose Li-Ion battery packs.

49. A power supply as claimed in claims 40 to 46 wherein said removable cartridge

battery packs are dual purpose cordless tool battery packs.

50. A power supply comprising a microprocessor, a first temperature sensor for sensing

the temperature within the power supply and a second sensor for sensing temperature

external to the power supply, said first and second sensor communicating with said

microprocessor, a plurality of removable cartridge battery packs, said microprocessor

selectively connecting or disconnecting each of said removable cartridge battery packs with a battery bus interconnected with a load depending on either or both of said temperatures.

51. A power supply a microprocessor, a plurality of removable cartridge battery packs,

each of said removable cartridge battery packs is selectively connected or disconnected

with a battery bus interconnected with a load, each of said removable cartridge battery

packs is selectively connected or disconnected with a charge bus, said microprocessor

selectively enables each of said removable cartridge battery packs to deliver power,

receive power, or to neither deliver nor receive power.

52. A power supply as claimed in claim 51 wherein said removable battery packs are Li-

Ion battery packs.

53. A power supply as claimed in claim 52 wherein said removable battery packs are

selected from the group of Li-Ion, Li-Ion solid polymer, Lead-Acid, NiMH and Alkaline.

54. A power supply as claimed in claim 51 wherein said microprocessor selectively

communicates with each of said plurality of removable battery packs.

55. A power supply comprising a microprocessor, a plurality of removable cartridge

battery packs, a thermal sensor in proximity with each of said removable battery packs,

said microprocessor being in communication with each thermal sensor and detecting the

ambient localized temperature of each of said removable battery pack, each of said

removable cartridge battery packs being controlled by said microprocessor, said

microprocessor selectively interconnects or disconnects each of said removable cartridge

battery packs with a battery bus interconnected with a load, said microprocessor

selectively interconnects or disconnects each of said removable cartridge battery packs

with a charge bus, said microprocessor selectively interconnects or disconnects each of said removable cartridge battery packs with a battery monitor bus, and, operation of each

of said removable battery pack is a function of the ambient temperature of each of said

removable battery pack.

56. A power supply comprising a microprocessor, a plurality of removable cartridge

battery packs, a thermal sensor in proximity with each of said removable battery packs,

said microprocessor being in communication with each thermal sensor and detecting the

ambient localized temperature of each of said removable battery pack, each of said

removable cartridge battery packs being controlled by said microprocessor, said

microprocessor selectively interconnects or disconnects each of said removable cartridge

battery packs with a battery bus interconnected with a load, said microprocessor

selectively interconnects or disconnects each of said removable cartridge battery packs

with a battery monitor bus, and, said microprocessor operates each of said removable

cartridge battery pack as a function of the current through each said removable cartridge

battery pack and said ambient localized temperature of each of said removable battery

pack.

57. A power supply as claimed in claim 55 wherein an optical transistor couples said

microprocessor and said thermal sensor.

58. A power supply as claimed in claim 56 wherein an optical transistor couples said

microprocessor and said thermal sensor.

59. A power supply comprising: a plurality of battery packs; each of said plurality of

battery packs includes a battery interface circuit; a microprocessor; said battery interface

circuit includes: a battery bus output branch having a first transistor operated by said microprocessor, a charging bus input branch having a second transistor operated by said

microprocessor, a battery bus monitoring branch having a third transistor operated by said

microprocessor, and, said microprocessor coupling said battery bus monitoring branch of

said battery interface circuit to said battery and periodically disconnecting each of said

battery packs from said battery bus output branch.

60. A power supply as claimed in claim 59 further comprising a temperature sensor in

proximity to each of said plurality of battery packs wherein said microprocessor

periodically operates a fourth transistor coupling said battery information bus of said

interface circuit to said temperature sensor.

61. A power supply as claimed in claim 59 wherein said microprocessor operates said

first and second transistors to direct current flow to said battery bus output branch and

said battery or to direct current flow to said battery based on information conveyed to said

microprocessor by said battery bus monitoring branch.

62. A power supply comprising a microprocessor, a plurality of battery packs, each of

said plurality of battery pack includes an interface circuit associated therewith, and, said

microprocessor operating each of said interface circuits selectively interconnecting

certain battery pack(s) with a load.

63. A power supply as claimed in claim 62 wherein said battery packs are cordless tool

battery packs.

64. A power supply as claimed in claim 63 wherein said battery packs are Li-Ion battery

packs.

65. A power supply as claimed in claim 62 wherein said battery packs are Li-Ion

polymer batter packs.

66. A power supply as claimed in claim 62 wherein said battery packs are NiMH.

67. A power supply as claimed in claim 62 wherein said battery packs are Alkaline.

68. A process for operating a power supply having a plurality of battery packs,

comprising the steps of:

selecting a battery pack for examination;

monitoring a battery bus output branch associated with the selected battery pack and

measuring the voltage thereon while supplying a load;

monitoring a battery bus output branch associated with the selected battery pack and

measuring the voltage thereon while disconnected from said load; and,

comparing the unloaded and loaded voltages.

69. A process for operating a power supply as claimed in claim 68 further comprising the

steps of:

applying charging current based on the difference between the unloaded and loaded

voltages.

70. A process for operating a power supply as claimed in claim 68 further comprising the

steps of:

permitting the selected battery to continue supplying the load based on the difference

between the unloaded and loaded voltages.

71. A process for operating a power supply as claimed in claim 68 further comprising the

steps of: applying charging current based on the difference between the unloaded and loaded

voltages; and,

permitting the selected battery to continue supplying the load based on the difference

between the unloaded and loaded voltages.

72. A process for operating a power supply having a plurality of battery packs,

comprising the steps of:

selecting a battery pack for examination;

monitoring a battery bus output branch associated with the selected battery pack and

measuring the voltage thereon while supplying a user defined load;

monitoring a battery bus output branch associated with the selected battery pack and

measuring the voltage thereon while a test resistor is switchably connected in parallel

with the user defined load; and,

comparing the voltage measured across the user defined load with the voltage measured

across the user defined load in parallel with the test resistor.

73. A process for operating a power supply as claimed in claim 72 further comprising the

steps of:

applying charging current based on the difference between the voltage measured across

the user defined load with the voltage measured across the user defined load in parallel

with the test resistor.

74. A process for operating a power supply as claimed in claim 72 further comprising the

steps of:

permitting the selected battery to continue supplying the user defined load.

75. A process for operating a power supply as claimed in claim 72 further comprising the

steps of:

applying charging current based on the difference between the voltage measured across

the user defined load with the voltage measured across the user defined load in parallel

with the test resistor; and,

permitting the selected battery to continue supplying the user defined load.

76. A process for operating a power supply having a plurality of battery packs,

comprising the steps of:

selecting a battery pack for examination;

monitoring a battery bus output branch associated with the selected battery pack and

measuring the voltage thereon while interconnected with a test resistor of known value;

monitoring a battery bus output branch associated with the selected battery pack and

measuring the voltage thereon while disconnected from said test resistor; and,

comparing the voltage measured across the user defined load with the voltage measured

across the user defined load in parallel with the test resistor.

77. A process for operating a power supply as claimed in claim 76 further comprising the

steps of:

applying charging current based on the difference between the voltage measured across

the user defined load with the voltage measured across the user defined load in parallel

with the test resistor.

78. A process for operating a power supply as claimed in claim 76 further comprising the

steps of: permitting the selected battery to continue supplying the user defined load based on the

difference between the voltage measured across the user defined load with the voltage

measured across the user defined load in parallel with the test resistor.

79. A process for operating a power supply as claimed in claim 76 further comprising the

steps of:

applying charging current based on the difference between the voltage measured across

the user defined load with the voltage measured across the user defined load in parallel

with the test resistor; and,

permitting the selected battery to continue supplying the user defined load based on the

difference between the voltage measured across the user defined load with the voltage

measured across the user defined load in parallel with the test resistor.

80. A process for operating a power supply having a plurality of battery packs,

comprising the steps of:

selecting a battery pack for examination; and,

measuring the external ambient temperature in the vicinity of the battery pack.

81. A process for operating a power supply having a plurality of battery packs,

comprising the steps of:

measuring the external ambient temperature in the vicinity of each of the battery packs;

selecting a battery pack(s) for operation and connection to a load;

monitoring a battery bus output branch associated with each of the selected battery packs

and measuring the voltages thereon while supplying a load; monitoring a battery bus output branch associated with each of the selected battery packs

and measuring the voltages thereon while disconnected from said load; and,

comparing the unloaded and loaded voltages of each respective battery selected for

operation and connection to said load.

82. A process for operating a power supply having a plurality of battery packs as claimed

in claim 81 further comprising the steps of:

selecting additional battery packs(s) for operation and connection to said load.

83. A process for operating a power supply having a plurality of battery packs as claimed

in claim 81 further comprising the steps of:

discontinuing operation of previously selected battery pack(s).

84. A process for operating a power supply having a plurality of battery packs as claimed

in claim 81 further comprising the steps of:

selecting additional battery packs(s) for operation and connection to said load; and,

discontinuing operation of previously selected battery pack(s).

85. A process for operating a power supply having a plurality of battery packs,

comprising the steps of:

monitoring a battery bus output branch associated with each of the selected battery packs

and measuring the voltages thereon while supplying a load, said load including a direct

current to direct current step up converter;

monitoring a battery bus output branch associated with each of the selected battery packs

and measuring the voltages thereon while disconnected from said load; comparing the unloaded and loaded voltages of each respective battery selected for

operation and connection to said load; and,

identifying battery packs to be charged depending on said comparison of said unloaded

and loaded voltages on each of the respective battery bus output branch(es);

86. A process for operating a power supply as claimed in claim 85 further comprising the

steps of

charging the identified battery packs.

87. A process for operating a power supply as claimed in claim 85 wherein said step of

charging the identified battery packs is performed at a voltage higher than the nominal

voltage of each of said battery packs.

88. A process for operating a power supply as claimed in claims 68-87 wherein said

battery packs are removable cartridge battery packs.

89. A power supply as claimed in claim 59 wherein each said battery bus output branch

and charging input bus branch include a diode to direct current flow in each interface

circuit.

90. A power supply as claimed in claim 60 wherein each said battery bus output branch

and charging input bus branch include a diode to direct current flow in each interface

circuit.

91. A power supply as claimed in claim 61 wherein each said battery bus output branch

and charging input bus branch include a diode to direct current flow in each interface

circuit.

92. A power supply as claimed in claim 62 wherein each said battery bus output branch

and charging input bus branch include a diode to direct current flow in each interface

circuit.

93. A power supply comprising a microprocessor and k batteries in parallel, where k is

any integer, each battery is switchably interconnected with k loads, a charge bus

switchably interconnected with said batteries, a monitor bus switchably interconnected

with said k batteries, and an r sense bus switchably interconnected with said batteries,

said microprocessor directing power into and out of each of said k batteries.

94. A power supply as claimed in claim 93 wherein said microprocessor prioritizes said k

loads and disconnects loads in a prescribed order.

95. A power supply as claimed in claim 93 wherein diodes direct current flow from said

k batteries toward k loads and direct current flow from said charge bus toward said k

batteries.

96. A rack for housing a plurality of removable cartridge batteries comprising at least one

shelf, each of said removable cartridge type batteries includes a first electrical contact and

a second electrical, said shelf includes first electrical connectors which matingly engage

said first electrical contacts of said battery and second electrical connectors which

matingly engage said second electrical contacts, and, first and second wires affixed to

each of said first and second electrical connectors.

97. A rack for housing a plurality of removable cartridge batteries as claimed in claim 96

wherein said shelves include printed circuits thereon.

98. A rack for housing a plurality of removable cartridge batteries as claimed in claim 97

wherein said printed circuits are battery interface circuits and wherein said first and

second connectors engage a portion of said printed circuit.

99. A rack for housing a plurality of removable cartridge batteries as claimed in claim 97

wherein said first and second wires associated with each battery are affixed to said

appropriate places of each printed circuit.

100. A rack for housing a plurality of removable cartridge batteries as claimed in claim

96 further comprising a battery interface circuit associated with each battery and wherein

said first and second wires are affixed to said battery interface circuit.

101. A rack for housing a plurality of removable cartridge batteries as claimed in claim

100 further comprising a printed battery interface circuit on a printed circuit board

attached to the rack.

102. A rack for housing a plurality of removable cordless tool batteries comprising at

least one shelf, each of said removable cordless tool batteries includes a first electrical

contact and a second electrical contact, said shelf includes first electrical connectors

which matingly engage said first electrical contacts of said battery and second electrical

connectors which matingly engage said second electrical contacts, and, first and second

wires affixed to each of said first and second electrical connectors.

103. A rack for housing a plurality of removable cartridge batteries as claimed in claim

97 wherein said shelves including printed circuits thereon also include connectors for

connection with a motherboard.

104. A rack for housing a plurality of removable cartridge batteries as claimed in claim

98 wherein said shelves including printed circuits thereon also include connectors for

connection with a motherboard.

105. A rack for housing a plurality of removable cartridge batteries comprising at least

one shelf, each of said removable cartridge type batteries includes a first electrical contact

and a second electrical contact, said shelf includes first electrical connectors which

matingly engage said first electrical contacts of said battery and second electrical

connectors which matingly engage said second electrical contacts, said at least one shelf

includes printed circuits, said printed circuits are battery interface circuits, said first and

second connectors engage a portion of said printed circuit, and said at least one shelf

includes a connector mounted thereon for connection with a motherboard.

106. A rack for housing a plurality of removable cartridge batteries as claimed in claim

105 further comprising a plurality of shelves each having a plurality of battery interface

circuits thereon interconnected with a connector mounted thereon for connection to a

motherboard.

107. A rack for housing a plurality of removable cartridge batteries comprising at least

one shelf, each of said removable cartridge type batteries includes a first electrical contact

and a second electrical, said shelf includes first electrical connectors which matingly

engage said first electrical contacts of said battery and second electrical connectors which

matingly engage said second electrical contacts, a printed circuit board affixed to said

rack, said printed circuit board includes a battery interface circuit and battery interface

connector corresponding to each of said removable cartridge type batteries, said first and second wires are affixed to each first and second electrical connector of each said battery

and to each respective battery interface connector enabling communication and control of

each of said removable cartridge batteries.

108. A rack for housing a plurality of removable cartridge batteries comprising a

plurality of shelves, said shelves arranged in a stack having a bottom shelf and a top shelf,

said shelves being vertically spaced apart each other, said shelves include a plurality of

bores therethrough, a plurality of interconnecting rods extending vertically through said

bores in said shelves, a plurality of hollow spacing tubes reside concentrically around said

plurality of interconnecting rods and intermediate each of said shelves spacing said

shelves apart; and, fasteners affixed to said interconnecting rods beneath said bottom

shelf and above said top shelf.

109. A rack for housing a plurality of removable cartridge batteries as claimed in claim

108 wherein a battery array is formed by said plurality of shelves in combination with

said spacing tubes and said interconnecting rods.

110. A rack for housing a plurality of removable cartridge batteries as claimed in claim

108 further comprising a frame fastener.

111. A rack for housing a plurality of removable cartridge batteries as claimed in claims

96 or 105 wherein said shelves are adapted to interlock with removable cartridge

batteries.

112. An enclosure for housing a battery rack having a plurality of batteries comprising at

least one frame portion, first and second fastening bars affixed to said frame portion, first

and second connecting rods attached to said first and second fastening bars and extending therefrom, said battery rack includes a frame fastener, and, said first and second fastening

bars interconnected with said frame fastener to secure said battery rack to said frame.

113. An enclosure for housing a battery rack having a plurality of batteries as claimed in

claim 112 further comprising a rearward portion and wherein an electrical motherboard is

mounted to said rearward portion.

114. An enclosure for housing a battery rack having a plurality of batteries as claimed in

claim 113 further comprising a front door portion and wherein said front door portion

includes a vent and a fan.

115. An enclosure for housing a battery rack having a plurality of batteries as claimed in

claim 114 wherein said front door portion further includes a lip enabling storage of said

rack during maintenance.

116. An enclosure for housing a plurality of battery racks each having a plurality of

batteries comprising a plurality of frame portions hinged together, and, each of said

battery racks resides in a frame portion.

117. An enclosure for housing a plurality of battery racks each having a plurality of

batteries as claimed in claim 116 wherein one of said frame portions is a rear portion.

118. An enclosure for housing a plurality of battery racks each having a plurality of

batteries as claimed in claim 117 wherein one of said frame portions is a front door

portion.

119. A power supply comprising a plurality of battery racks each having a plurality of

batteries, a plurality of frame portions hinged together, and, each of said battery racks

resides in a frame portion.

120. A power supply comprising a plurality of battery racks each having a plurality of

batteries as claimed in claim 119 wherein one of said frame portions is a rear portion.

121. A power supply comprising a plurality of battery racks each having a plurality of

batteries as claimed in claim 119 wherein one of said frame portions is a front door

portion.

122. A power supply comprising a plurality of battery racks each having a plurality of

batteries as claimed in claim 119 wherein one of said frame portions is a rear portion and

wherein one of said frame portions is a front door portion.

123. A power supply comprising a plurality of battery racks each having a plurality of

batteries as claimed in claim 122 wherein an electrical motherboard is mounted to said

rearward portion and wherein said front door portion includes a vent and a fan.

124. A process for servicing a power supply which includes a plurality of frame portions

hinged together, each frame securing an arrayed rack of batteries, comprising the steps of:

unlocking a frame from the next adjacent frame; and,

rotating said next adjacent frame to expose the frame to be serviced.

125. A process for servicing a power supply which includes a plurality of frame portions

hinged together, each frame securing an arrayed rack of batteries as claimed in claim 124,

wherein the next adjacent frame includes a motherboard for controlling each said rack of

said plurality of arrayed batteries.

126. A process for servicing a power supply which includes a plurality of frame portions

hinged together, each frame securing an arrayed rack of batteries as claimed in claim 124,

wherein the next adjacent frame includes a front door having a vent and a fan.

127. A process for servicing a power supply which includes a plurality of frame portions

hinged together, each frame securing an arrayed rack of batteries as claimed in claim 124,

further comprising the steps of:

separating the hinged portions by removing the pin from the hinge.

128. A process for controlling a power supply having k inputs and n outputs, comprising

the steps of:

sensing the availability of the inputs;

measuring the inputs;

charging one or more of the inputs;

converting the inputs; and,

controlling the power to the outputs and the inputs.

129. A process for controlling a power supply having k inputs and n outputs as claimed in

claim 128 wherein one or more of the inputs is a plurality of battery packs arrayed in

parallel with each other.

130. A process for controlling a power supply having k inputs and n outputs as claimed

in claim 128 wherein said inputs are a combination of alternating current and direct

current inputs.

131. A process for controlling a power supply having k inputs and n outputs as claimed

in claim 128 wherein said outputs are a combination of alternating current and direct

current outputs.

132. A power supply comprising:

an alternating current input source selectively coupled to an AC/DC converter;

said AC/DC converter selectively coupled with an intermediate DC bus, a second DC bus

and a third DC bus;

a first, second, and third direct current input source selectively coupled with said

intermediate DC bus, a first DC bus, said second DC bus and said third DC bus;

said intermediate DC bus selectively coupled with a first DC output, a DC/AC inverter,

and a third DC/DC converter;

said third DC/DC converter being coupled to a second DC output and a third DC output;

said first DC bus coupled to a first DC/DC converter;

said first DC/DC converter selectively coupled to said intermediate DC bus, said third DC

bus and a DC charge bus;

said second DC bus coupled to a second DC/DC converter;

said second DC/DC converter selectively coupled to said intermediate DC bus, said third

DC bus and said DC charge bus;

said third DC bus coupled to a fourth DC output and said third DC bus is selectively

coupled to a fourth DC/DC converter;

said fourth DC/DC converter being coupled to a fifth and sixth direct current output; and,

said charge bus coupled to said third direct current input source.

133. A power supply as claimed in claim 132 wherein each direct current bus is coupled

to its energy source by a diode.

134. A power supply as claimed in claim 132 wherein all selectively coupling is

performed by switches.

135. A power supply as claimed in claim 132 wherein all selectively coupling is

performed by transistors.

136. A power supply as claimed in claim 135 wherein said transistor is a PFET.

137. A power supply comprising:

an alternating current input source switchably interconnected to an AC/DC converter;

said AC/DC converter includes an output switchably interconnected with an intermediate

DC bus, a second DC bus and a third DC bus;

a first, second, and third direct current input source switchably interconnected with said

intermediate DC bus, a first DC bus, said second DC bus and said third DC bus;

said intermediate DC bus switchably interconnected with a first DC output, a DC/AC

inverter, and a third DC/DC converter;

said third DC/DC converter being switchably interconnected to a second DC output and a

third DC output;

said first DC bus coupled to a first DC/DC converter;

said first DC/DC converter switchably interconnected to said intermediate DC bus, said

third DC bus and a DC charge bus;

said second DC bus switchably interconnected to a second DC/DC converter; said second DC/DC converter switchably interconnected to said intermediate DC bus,

said third DC bus and said DC charge bus;

said third DC bus coupled to a fourth DC output and said third DC bus is selectively

coupled to a fourth DC/DC converter;

said fourth DC/DC converter being coupled to a fifth and sixth direct current output; and,

said charge bus coupled to said third direct current input source.

138. A power supply as claimed in claim 137 further comprising a diode downstream of

every switchable interconnection.

139. A power supply as claimed in claim 137 where every switchable interconnection is

a PFET.

140. A power supply as claimed in claim 132 where all selective coupling is controlled

by a microprocessor.

141. A power supply as claimed in claim 137 where all switchable connections are

controlled by a microprocessor.

142. A power supply comprising:

an alternating current input source selectively coupled to an AC/DC converter;

said AC/DC converter selectively coupled with a DC bus;

an arrayed battery direct current input source comprising a plurality of batteries

selectively coupled with said DC bus;

said DC bus coupled to a DC/DC converter which is coupled to said battery array to

selectively charge any one or more of said arrayed batteries; and,

said DC bus is coupled to an output.

143. A power supply comprising:

an input source power source selectively coupled to a DC bus;

an arrayed battery direct current input source comprising a plurality of batteries

selectively coupled with said DC bus;

said DC bus coupled to said battery array to selectively charge any one or more of said

arrayed batteries; and,

said DC bus is coupled to an output.

144. A power supply as claimed in claim 143 wherein said input source is an alternating

current source.

145. A power supply as claimed in claim 143 wherein said input source is a direct current

source.

146. A power supply as claimed in claim 143 wherein said input source is a combination

of alternating current and direct current sources.

147. A power supply as claimed in claims 142-146 wherein all selective coupling is

performed by switches.

148. A power supply as claimed in claims 142-146 wherein all selectively coupling is

performed by transistors.

149. A power supply as claimed in claims 148 wherein said transistor are PFET.

150. A power supply comprising:

an plurality of input power sources selectively coupled to a DC bus;

a plurality of batteries selectively coupled with said DC bus; said DC bus selectively coupled to said battery array to selectively charge any one or

more of said plurality of batteries; and,

said DC bus is coupled to plurality of output.

151. A power supply comprising:

a direct current input source selectively coupled with, a DC bus;

an arrayed battery direct current input source comprising a plurality of batteries

selectively coupled with said DC bus;

said DC bus coupled to a DC/DC converter which is coupled to said battery array to

selectively charge any one or more of said arrayed batteries; and,

said DC bus is coupled to an output.

152. A power supply as claimed in claims 151-152 wherein all selectively coupling is

performed by switches.

153. A power supply as claimed in claims 151-152 wherein all selectively coupling is

performed by transistors.

154. A power supply as claimed in claim 153 wherein said transistors are PFET.

155. A power supply as claimed in claims 142 to 154 wherein all selective coupling is

controlled by a microprocessor.

156. A power supply comprising k inputs, 1 inverters, m converters, n outputs, and a

microprocessor, said microprocessor measuring the output voltages and currents of said k

inputs, 1 inverters, m converters and n outputs and applying a control algorithm based on

said voltages and currents.

157. A power supply as claimed in claim 156 wherein said microprocessor measures

ambient temperature in proximity to said 1 inverters and m converters and applies said

control algorithm based on said voltages, currents and temperatures.

158. A power supply as claimed in claim 157 wherein said microprocessor measures

ambient temperature on the interior of the power supply and externally to the power

supply and applies said control algorithm based on said voltages, currents and

temperatures.

159. A power supply as claimed in claims 4, 9-22, 25, 28-31, 36-40, 44, 50, 51, 54-62,

93, 94, 140, 141 and 155-158 wherein said microprocessor is programmable via an

Ethernet connection.

160. A power supply comprising:

a plurality of user defined alternating current input sources selectively coupled to an

AC/DC converter;

said AC/DC converter selectively coupled with a DC bus;

a plurality of user defined direct current input sources selectively coupled with said DC

bus;

an arrayed battery direct current input source comprising a plurality of batteries

selectively coupled with said DC bus;

said DC bus coupled to a DC/DC converter which is coupled to said battery array to

selectively charge any one or more of said arrayed batteries;

said DC bus is coupled to an output; a microprocessor switchably interconnected with said battery of said plurality of batteries

and interconnected with voltage, current and temperature sensors associated with said

sources and said converters;

said microprocessor applying an algorithm to control the power management, use and

output from said power supply.

161. A process for controlling a power supply, comprising the steps of:

measuring voltages and currents of each input source and output load; and, routing

power between said inputs and said outputs and said inputs.

162. A process for controlling a power supply as claimed in claim 161 further comprising

the steps of:

measuring voltages, currents and temperatures of internal buses and converters.

163. A process for controlling a power supply as claimed in claim 162 further comprising

the steps of measuring temperatures within an enclosure housing said power supply and

measuring temperatures externally to said power supply.

164. A process for controlling a power supply, said power supply including:

an alternating current input source selectively coupled to an AC/DC converter; said

AC/DC converter selectively coupled with an intermediate DC bus, a second DC bus and

a third DC bus; a first, second, and third direct current input source selectively coupled

with said intermediate DC bus, a first DC bus, said second DC bus and said third DC bus;

said intermediate DC bus selectively coupled with a first DC output, a DC/AC inverter,

and a third DC/DC converter; said third DC/DC converter being coupled to a second DC

output and a third DC output; said first DC bus coupled to a first DC/DC converter; said first DC/DC converter selectively coupled to said intermediate DC bus, said third DC bus

and a DC charge bus; said second DC bus coupled to a second DC/DC converter; said

second DC/DC converter selectively coupled to said intermediate DC bus, said third DC

bus and said DC charge bus; said third DC bus coupled to a fourth DC output and said

third DC bus is selectively coupled to a fourth DC/DC converter; said fourth DC/DC

converter being coupled to a fifth and sixth direct current output; and, said charge bus

coupled to said third direct current input source, comprising the steps of:

measuring voltages and currents of each input source and output load interconnected with

an interface to a microprocessor;

measuring voltages, currents and temperatures of internal buses and converters

interconnected with an interface to a microprocessor;

applying a programmable control algorithm to control the selective coupling of said input

sources, said converters, and said buses; and,

routing power between said inputs, said outputs and back to said inputs.

165. A process for controlling a power supply as claimed in claim 164 wherein at least

one of the inputs is an array of battery packs.

166. A process for controlling a power supply as claimed in claim 165 wherein said

battery packs are Li-Ion battery packs.

167. A process for controlling a power supply as claimed in claim 166 wherein said

battery packs are NiMH battery packs.

168. A process for controlling a power supply as claimed in claim 166 wherein said

battery packs are Li-Ion polymer battery packs.

169. A process for controlling a power supply as claimed in claim 166 wherein said

battery packs are lead acid battery packs.

170. A process for controlling a power supply as claimed in claim 166 wherein said

battery packs are alkaline battery packs.

171. A process for controlling a power supply, comprising the steps of:

measuring voltages and currents of each input source and output load interconnected with

an interface to a microprocessor;

measuring voltages, currents and temperatures of internal buses and converters

interconnected with an interface to a microprocessor;

applying a programmable control algorithm to control the routing of power between said

inputs, said outputs and back to said inputs.

172. A power supply comprising a plurality of removable cartridge battery packs wherein

a portion of said plurality includes batteries having a first chemistry and the remainder of

said plurality is comprised of batteries having a second chemistry.

173. A power supply as claimed in claim 172 wherein said first portion of said batteries

is selected from the group consisting of Li-Ion, Li-Ion polymer, NiCd, lead-acid, alkaline

and NiMH.

174. A power supply as claimed in claim 172 wherein said second portion of said

batteries is selected from the group consisting of Li-Ion, Li-Ion polymer, NiCd, lead-acid,

alkaline and NiMH.

175. A power supply comprising a first direct current to direct current converter and a

second direct current to direct current converter, and, said first and second converters

having adjustable output voltages.

176. A power supply as claimed in claim 175 further comprising a microprocessor

coupled to said first and second converters for controlling said output voltages of said

converters.

177. A power supply as claimed in claims 175 or 176 wherein said converters each have

an oring diode located on the outputs of said converters and said converters are ored

together.

178. A power supply as claimed in claim 177 wherein said diodes are Schottky diodes.

179. A power supply comprising:

a user defined direct current input source;

an arrayed battery direct current input source comprising a plurality of batteries;

a first direct current to direct current converter coupled with said user defined direct

current input source and a second direct current to direct current converter coupled with

said arrayed battery direct current input source, and, said first and second converters

having adjustable output voltages; and,

a microprocessor coupled to said first and second converters for controlling said output

voltages of said converters and the contribution of each of said direct current sources to

the energy flowing on said DC bus.

180. A power supply as claimed in claim 179 wherein said converters have an oring

diode located on said outputs of said converters and said converters are ored together.

181. A power supply as claimed in claim 180 wherein said diodes are Schottky diodes.

182. A power supply comprising:

a user defined alternating current input coupled with an alternating current to direct

current converter;

an arrayed battery direct current input source comprising a plurality of batteries;

a first direct current to direct current converter coupled with said user defined direct

current input source and a second direct current to direct current converter coupled with

said arrayed battery direct current input source, and, said first and second converters

having adjustable output voltages;

a DC bus coupled to said battery array to selectively charge any one or more of said

arrayed batteries and said DC bus is coupled to an output;

a microprocessor coupled to said first and second converters for controlling said output

voltages of said converters and the contribution of each of said direct current sources to

the energy flowing on said DC bus.

183. A process for controlling a power supply having first and second direct current to

direct current converters outputting to a common bus, comprising the steps of:

controlling the output voltage of each of said direct current to direct current converters

using a microprocessor.

184. A process for controlling a power supply as claimed in claim 183 wherein each of

said converters is arranged in a diode oring fashion coupled to said common bus.

185. A power supply comprising a plurality of removable cartridge battery packs in

parallel, a direct current to alternating current inverter, and at least one alternating current

output.

186. A power supply as claimed in claim 185 wherein said removable cartridge battery

packs are arranged in parallel with each other and include a common battery bus for

communicating power to said inverter, each of said battery packs includes an output and a

diode arranged in series with said output of said battery pack communicating power to

said common battery bus.

187. A power supply as claimed in claim 186 further comprising a DC to DC converter

interposed between said common battery bus and said inverter.

188. A power supply as claimed in claim 187 further comprising an AC input.

189. A power supply as claimed in claim 188 further comprising an AC-DC converter

communicating with said AC input.

190. A power supply as claimed in claim 189 wherein said output of said AC-DC

converter is ored together with said output of said common battery bus.

191. A power supply as claimed in claim 190 wherein said output of said AC-DC

converter is interconnected with a diode and said common battery bus is interconnected

with a diode and wherein said diodes are interconnected in an oring fashion.

192. A power supply as claimed in claim 191 wherein said interconnection of said diodes

is interconnected with said DC-AC inverter.

193. A power supply comprising at least one removable cartridge battery pack.

194. A power supply as claimed in claim 193 further comprising a plurality of

removable cartridge battery packs.

195. A power supply as claimed in claim 193 wherein each of at least one

removable cartridge battery pack is of a quick-disconnect, rechargeable type.

196. A power supply as claimed in claim 193 further comprising a microprocessor

wherein the operation of each of at least one removable cartridge battery pack is

controlled by said microprocessor.

197. A power supply as claimed in claim 193 wherein each of at least one

removable cartridge battery pack is selectively interconnected to a load and is

selectively disconnected from said load under the control of said microprocessor.

198. A power supply as claimed in claim 196 further comprising a charging circuit

wherein each of at least one removable cartridge battery pack is selectively

interconnected to said charging circuit and is selectively disconnected from said

charging circuit under the control of said microprocessor.

199. A power supply as claimed in claim 196 further comprising a battery

information bus wherein each of at least one removable cartridge battery pack is

selectively interconnected to said battery information bus and is selectively

disconnected from said battery information bus under the control of said

microprocessor.

200. A power supply as claimed in claim 196 wherein each of at least one

removable cartridge battery pack has an output voltage.

201. A power supply as claimed in claim 200 further comprising a battery monitor

bus wherein each of at least one removable cartridge battery pack is selectively

interconnected to said battery monitor bus and is selectively disconnected from

said battery monitor bus under the control of said microprocessor.

202. A power supply as claimed in claim 201 wherein said microprocessor

measures said output voltage of said cartridge battery pack when it is selectively

interconnected with said battery monitor bus.

203. A power supply as claimed in claim 193 wherein any of at least one

removable cartridge battery pack are dual-purpose battery packs.

204. A power supply as claimed in claim 196, further comprising N loads and N

load switches for each of at least one removable cartridge battery pack wherein

each of at least one removable cartridge battery pack is switchably interconnected

or disconnected with any of said N loads under the control of said microprocessor.

205. A power supply as claimed in claim 204 wherein at least one of said N loads

is a DC to DC, voltage step up or voltage step down, power conversion unit.

206. A power supply as claimed in claim 204 wherein at least one of said N loads

is a DC to AC power conversion unit.

207. A power supply as claimed in claim 205 wherein the output voltage of said

DC to DC power conversion unit may be adjusted under the control of said

microprocessor.

208. A power supply as claimed in claim 206 wherein the output of said DC to DC

power conversion unit is switchably interconnected to charge at least one

removable cartridge battery pack under the control of said microprocessor.

209. A power supply comprising a plurality of quick disconnect removable

cartridge battery packs, each of said removable cartridge battery packs is

selectively interconnected to a battery bus interconnected with a load, each of said

removable cartridge battery packs is selectively interconnected to a charge bus,

and, each of said removable cartridge battery packs is selectively interconnected to

a battery monitor bus.

210. A power supply as claimed in claim 209 further comprising a

microprocessor, said microprocessor selectively interconnecting a first portion of

said plurality of removable cartridge battery packs with said battery bus, said

microprocessor selectively interconnecting a second portion of said plurality of

removable cartridge battery packs with said charge bus, said microprocessor

selectively interconnecting a third portion of said plurality of removable cartridge

battery packs with both said battery bus and said charge bus, and, said

microprocessor selectively disconnecting a fourth portion of said plurality of removable cartridge packs from both said charge bus and said battery bus, n claim

wherein said first, second, third and fourth portions of said plurality of removable

cartridge battery packs may include one, more than one, all, or none of the plurality

of removable cartridge battery packs.

211. A battery electric vehicle power supply system comprising at least one

removable cartridge battery pack, a battery bus, a charge bus, a battery monitor

bus, a battery information bus, switches between each of at least one removable

cartridge battery pack and each of said battery bus, charge bus, battery monitor

bus, and battery information bus, and a microcontroller, said microcontroller

selectively connecting or disconnecting each of at least one removable cartridge

battery pack from each of said battery bus, charge bus, battery monitor bus, or

battery information bus by controlling said switches, said battery bus being

connected to said battery electric vehicle motor system so as to provide power for

said motor system, said charge bus being connected to said vehicle motor system

so as to recapture regenerative energy from said system for the purposes of

recharging at least one removable cartridge battery pack.

212. A battery electric vehicle service station comprising at least one removable

cartridge battery pack, a battery bus, a charge bus, a battery monitor bus, a battery

information bus, switches between each of at least one removable cartridge battery

pack and each of said battery bus, charge bus, battery monitor bus, and battery information bus, and a microcontroller, said microcontroller selectively connecting

or disconnecting each of at least one removable cartridge battery pack from each of

said battery bus, charge bus, battery monitor bus, or battery information bus by

controlling said switches.

213. A process for operating a power supply having a plurality of battery

packs, comprising the steps of:

selecting a battery pack for examination;

connecting said selected pack to a first combination of loads and charging

current including no loads and no charging current;

measuring said selected pack first output voltage while connected to said

first combination of loads and charging current;

connecting said selected pack to a second combination of loads and charging

current, different from said first combination of loads and charging current,

including no loads and no charging current;

measuring said selected pack second output voltage while connected to said

second combination of loads and charging current;

comparing said first output voltage to said second output voltage; and,

connecting said selected pack to a third combination of loads and charging

current, including no loads and no charging current, based upon the result of

comparing said first output voltage to said second output voltage.

214. A process for operating a power supply having a plurality of battery packs,

comprising the steps of:

interconnecting each of said battery packs with a combination of loads, a

charging current, or any combination of said loads and charging current including

no load and no charging current.

215. A process as claimed in claim 214 comprising the further step of:

deciding the interconnection state of each of said batteries based on at least

one system parameter.

216. A process as claimed in claim 215 wherein said system parameter is voltage.

217. A process as claimed in claim 215 wherein said system parameter is

temperature.

218. A process as claimed in claim 215 wherein said system parameter is current.

219. A process as claimed in claim 215 wherein said system parameter is battery

capacity.

220. A process as claimed in claim 215 wherein said system parameter is battery

state of charge.

221. A process for operating a power supply having a plurality of power

converters, each having an adjustable output, comprising the steps of:

measuring the output of each of said power converters; and, adjusting the output of each of said power converters as required to achieve

a desired output.

222. A process for operating a power supply as claimed in claim 221, wherein each

of said power converters share a common output load.

223. A process for operating a power supply as claimed in claim 221, wherein each

of said power converters share a common input power source.

224. A process for operating a power supply, comprising the steps of:

measuring the voltage of and current in each input and output; and,

mixing power between said inputs and said outputs and said inputs.

225. A process for operating a power supply as claimed in claim 224 further

comprising the step of:

measuring the voltage of, the current in, and the temperature of each internal

bus and each power converter.

226. A process for operating a power supply as claimed in claim 225 further

comprising the steps of:

measuring temperatures within an enclosure housing said power supply; and,

measuring temperatures external to said power supply enclosure.

227. A process for operating a power supply as claimed in claim 224 where at

least one of the inputs is an array of battery packs.

228. A process for operating a power supply as claimed in claim 227 wherein said

battery packs are Li-ion battery packs.

229. A process for operating a power supply as claimed in claim 227 wherein said

battery packs are removable cartridge battery packs.

230. A process for operating a power supply having a plurality of battery packs,

comprising the steps:

measuring the temperature of said battery packs; and,

determining the interconnection of said battery packs to system loads based

on their temperature.

231. A process for operating a power supply having a plurality of battery packs,

comprising the steps of:

measuring the state of charge of each of said battery packs during discharge

of each of said batteries;

terminating discharge of each battery at a given threshold state of charge;

measuring the state of charge of each battery during charging;

terminating charging at second threshold.

232. The process of refueling a battery electric vehicle comprising the steps of:

removing discharged removable cartridge battery packs from said vehicle;

replacing said packs with charged removable cartridge battery packs; calculating the charge energy level and condition of removed removable

cartridge battery packs;

calculating the charge energy level and condition of replaced removable

cartridge battery packs;

calculating a refueling fee based upon the difference of the calculated charge

energy levels and conditions of removed versus replaced removable cartridge

battery packs;

recharging removed removable cartridge battery packs; and,

rendering removed removable cartridge battery packs suitable for resale as

replacement removable cartridge battery packs.

233. A power supply comprising a plurality of battery racks each having a plurality of

batteries as claimed in 123 wherein said motherboard is connected to each of said battery

racks.