US2022320877A1PendingUtilityA1

All-electric mobile power unit with variable outputs

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Assignee: MOXION POWER COPriority: Jun 1, 2020Filed: Mar 17, 2022Published: Oct 6, 2022
Est. expiryJun 1, 2040(~13.9 yrs left)· nominal 20-yr term from priority
Inventors:Alexander J. SmithPaul M. HuelskampAlexander M. MeekJared T. Mickle
H02J 7/731H02J 7/70H02J 2105/10H02J 7/855H02J 9/04H02M 7/44H02M 1/327H02M 3/1586H02M 7/48H02M 1/007H02J 7/342H02J 7/14H02J 7/0042H02J 7/0044
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Claims

Abstract

An all-electric, battery powered industrial or commercial mobile power unit is provided that can include a number of features. The mobile power unit can include a DC electrical energy source configured to produce a voltage of approximately 300-450 VDC. The mobile power unit can be configured so as to produce a user programmable voltage output and/or a user selected voltage output of either 480 VAC 3-phase, 208 VAC 3-phase, or 240 VAC single-phase. The various output configurations are controlled by software with a system controller of the mobile power unit. Methods of use are also provided.

Claims

exact text as granted — not AI-modified
1 . An all-electric, battery powered mobile power unit, comprising:
 a DC electrical energy source;   a power conversion system coupled to the DC electrical energy source, wherein the power conversion system includes a plurality of inverter stages and does not include a transformer; and   an electronic controller configured to control operation of the power conversion system to produce a user-selected voltage output ranging from 100 VAC up to 500 VAC and a user-selected phase configuration.   
     
     
         2 . The mobile power unit of  claim 1 , wherein the power conversion system comprises:
 a high voltage DC/DC converter electrically coupled to the DC electrical energy source; and   wherein the plurality of inverter stages are electrically coupled to the high voltage DC/DC converter.   
     
     
         3 . The mobile power unit of  claim 1 , wherein the user-selected phase configuration is selected from the group consisting of single-phase and 3-phase. 
     
     
         4 . The mobile power unit of  claim 1 , wherein the user-selected voltage output and phase configuration is selected from the group consisting of 480 VAC 3-phase, 208 VAC 3-phase, and 240 VAC single-phase. 
     
     
         5 . The mobile power unit of  claim 4 , wherein when the user-selected voltage output and phase configuration comprises 480 VAC 3-phase, the electronic controller is configured to:
 control the high voltage DC/DC converter to operate as a boost converter in which a primary battery voltage from the DC electrical energy source is increased to a secondary voltage; and   control the plurality of inverter stages to phase shift the outputs of the plurality of inverter stages to be 120 degrees apart.   
     
     
         6 . The mobile power unit of  claim 5 , wherein the primary battery voltage from the DC electrical energy source comprises 300-450 VDC and the secondary voltage comprises 800 VDC. 
     
     
         7 . The mobile power unit of  claim 5 , wherein:
 a neutral line corresponding to a first output of a first of the plurality of inverter stages is in phase with a line L 1  corresponding to a second output of a second of the plurality of inverter stages;   a line L 2  corresponding to a third output of a third of the plurality of inverter stages is phase shifted by 120 degrees from the line L 1 ; and   a line L 3  corresponding to a fourth output of a fourth of the plurality of inverter stages is phase shifted by 120 degrees from the line L 2 .   
     
     
         8 . The mobile power unit of  claim 7 , wherein the electronic controller is configured to provide the 480 VAC 3-phase output to only a subset of electrical connections on an interface panel of the mobile power unit. 
     
     
         9 . The mobile power unit of  claim 8 , wherein the electronic controller is configured to provide the 480 VAC 3-phase output to only one or more tapered nose cam lock connectors or one or more threaded fastener style connectors on the interface panel of the mobile power unit. 
     
     
         10 . The mobile power unit of  claim 9 , wherein the electronic controller is configured to trigger circuit breakers associated with duplex connectors or CS6365 connectors on the interface panel of the mobile power unit to prevent the 480 VAC 3-phase output from reaching the duplex connectors or CS6365 connectors. 
     
     
         11 . The mobile power unit of  claim 4 , wherein when the user-selected voltage output and phase configuration comprises 208 VAC 3-phase, the electronic controller is configured to:
 control the high voltage DC/DC converter to operate as a pass-through, in which a primary battery voltage from the DC electrical energy source is provided as a secondary voltage; and   control the plurality of inverter stages to phase shift the outputs of the plurality of inverter stages to be 120 degrees apart.   
     
     
         12 . The mobile power unit of  claim 11 , wherein the primary battery voltage from the DC electrical energy source comprises 300-450 VDC and the secondary voltage also comprises 300-450 VDC. 
     
     
         13 . The mobile power unit of  claim 11 , wherein:
 a neutral line corresponding to a first output of a first of the plurality of inverter stages is in phase with a line L 1  corresponding to a second output of a second of the plurality of inverter stages;   a line L 2  corresponding to a third output of a third of the plurality of inverter stages is phase shifted by 120 degrees from the line L 1 ; and   a line L 3  corresponding to a fourth output of a fourth of the plurality of inverter stages is phase shifted by 120 degrees from the line L 2 .   
     
     
         14 . The mobile power unit of  claim 11 , wherein the electronic controller is configured to provide the 208 VAC 3-phase output to only a subset of electrical connections on an interface panel of the mobile power unit. 
     
     
         15 . The mobile power unit of  claim 14 , wherein the electronic controller is configured to provide the 208 VAC 3-phase output to only one or more tapered nose cam lock connectors, one or more threaded fastener style connectors, or one or more duplex connectors on the interface panel of the mobile power unit. 
     
     
         16 . The mobile power unit of  claim 15 , wherein the electronic controller is configured to trigger circuit breakers associated with CS6365 connectors on the interface panel of the mobile power unit to prevent the 208 VAC 3-phase output from reaching the CS6365 connectors. 
     
     
         17 . The mobile power unit of  claim 4 , wherein when the user-selected voltage output and phase configuration comprises 240 VAC single-phase, the electronic controller is configured to:
 control the high voltage DC/DC converter to operate as a pass-through, in which a primary battery voltage from the DC electrical energy source is provided as a secondary voltage; and   control the plurality of inverter stages to phase shift first and second outputs of the plurality of inverter stages to be 180 degrees apart.   
     
     
         18 . The mobile power unit of  claim 17 , wherein the primary battery voltage from the DC electrical energy source comprises 300-450 VDC and the secondary voltage also comprises 300-450 VDC. 
     
     
         19 . The mobile power unit of  claim 17 , wherein:
 a neutral line corresponding to a first output of a first of the plurality of inverter stages is in phase with a line L 1  corresponding to a second output of a second of the plurality of inverter stages, and is in phase with a line L 3  corresponding to a third output of a third of the plurality of inverter stages;   a line L 2  corresponding to a fourth output of a fourth of the plurality of inverter stages is phase shifted by 180 degrees from the neutral line, the line L 1 , and the line L 3 .   
     
     
         20 . The mobile power unit of  claim 19 , wherein the electronic controller is configured to provide the 240 VAC single-phase output to only a subset of electrical connections on an interface panel of the mobile power unit. 
     
     
         21 . The mobile power unit of  claim 20 , wherein the electronic controller is configured to provide the 240 VAC single-phase output to only one or more duplex connectors or one or more CS6365 connectors on the interface panel of the mobile power unit. 
     
     
         22 . The mobile power unit of  claim 20 , wherein the electronic controller is configured to trigger circuit breakers associated with tapered nose cam lock connectors or the threaded fastener style connectors on the interface panel of the mobile power unit to prevent the 240 VAC single-phase output from reaching the tapered nose cam lock connectors or the threaded fastener style connectors. 
     
     
         23 . The mobile power unit of  claim 1 , wherein the user-selected voltage output comprises any chosen voltage between 100 VAC and 500 VAC. 
     
     
         24 . The mobile power unit of  claim 1 , wherein the DC electrical energy source comprises at least 600 kWh of energy storage. 
     
     
         25 . The mobile power unit of  claim 1 , wherein the DC electrical energy source comprises at least 500 kWh of energy storage. 
     
     
         26 . The mobile power unit of  claim 1 , wherein the DC electrical energy source comprises at least 750 kWh of energy storage. 
     
     
         27 . A method of delivering a user-selected voltage output with an all-electric, battery powered industrial mobile power unit, comprising the steps of:
 receiving a desired voltage output ranging from 100V AC up to 500V AC and a desired phase configuration from a user;   controlling operation of a power conversion system of the mobile power unit with an electronic controller of the mobile power unit to produce the desired voltage output and the desired phase configuration without using a transformer.   
     
     
         28 . The method of  claim 27 , wherein controlling operation of the power conversion system further comprises controlling operation of a high voltage DC/DC converter and a plurality of inverter stages of the mobile power unit with the electronic controller. 
     
     
         29 . The method of  claim 27 , wherein the desired voltage output and phase configuration is selected from the group consisting of 480 VAC 3-phase, 208 VAC 3-phase, and 240 VAC single-phase. 
     
     
         30 . The method of  claim 27 , wherein the desired voltage output is between 100 VAC and 500 VAC.

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