CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63/295,436, filed December 30, 2021, for “SUPERCAPACITOR SYSTEM WITH A OVER VOLTAGE PRODUCTION CAPABILITY,” the disclosure of which is incorporated herein by referent in its entirety.

FIELD OF THE DISCLOSURE

[0002] The present disclosure is generally related to a supercapacitor system having an over voltage protection capability.

BACKGROUND

[0003] Supercapacitors can work with batteries or be used in alternative to batteries in applications needing many rapid charge/discharge cycles. A supercapacitor can small operating voltages (2.7V to 5V), applications of these supercapitors can use an array of devices connected in series for higher voltage. Supercapacitors can have a leakage current that varies based on numerous factors, including initial leakage value, leakage variation with charging voltage, charging current and temperature, operating temperature range, chemistry, material, and construction and aging. Across supercapacitor unit cells, there are differences in leakage currents between individual supercapacitors, resulting in changes in voltages over time; this can cause reduced lifespan and eventual failure since exceeding the maximum voltage on a supercapacitor can lead to unit cell failure.

SUMMARY

[0004] Disclosed herein are systems and methods for overvoltage protection. A system, such as a vehicle, for overvoltage protection of a supercapacitor system for an electric vehicle, the system includes a plurality of supercapacitor groups, each supercapacitor group comprising two or more of the plurality of supercapacitors. The system includes a plurality of overvoltage protector units, each the plurality of overvoltage protector units operable to detect the voltage of each of the two or more supercapacitors within the respective one of the supercapacitor groups. The system includes a controller comprising a processor with access to a memory, wherein the control system is operable to determine which of the plurality of supercapacitor groups to connect to the electric vehicle based on data sent from the respective overvoltage protector units.

[0005] In an illustrative example, a system is disclosed for overvoltage protection. The system comprises: a plurality of supercapacitor groups, each supercapacitor group comprising two or more of the plurality of supercapacitors; a plurality of overvoltage protector units, each the plurality of overvoltage protector units operable to detect the voltage of each of the two or more supercapacitors within the respective one of the supercapacitor groups; a controller comprising a processor with access to a memory, wherein the control system is operable to determine which of the plurality of supercapacitor groups to connect to the electric vehicle based on data sent from the respective overvoltage protector units.

[0006] In another illustrative example, a method is disclosed for overvoltage protection. The method comprises: measuring, using an overvoltage protector unit, a voltage of a plurality of a plurality of supercapacitor groups, each group comprising a plurality of supercapacitors; determining, by a processor, which of the plurality of supercapacitor groups to connect to the electric vehicle based on the voltage of each of the plurality of supercapacitor groups.

BRIEF DESCRIPTIONS OF THE DRAWINGS

[0007] The accompanying drawings illustrate various embodiments of systems, methods, and other aspects of the embodiments. Any person with ordinary art skills will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent an example of the boundaries. It may be understood that, in some examples, one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another and vice versa. Furthermore, elements may not be drawn to scale. Non-limiting and non-exhaustive descriptions are described with reference to the following drawings. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating principles. [0008] FIG. 1 is a block diagram illustrating an architecture of a supercapacitor system having an overvoltage protection capability, according to some examples.

[0009] FIG. 2 is a flow diagram illustrating a process performed using a base module, according to some examples.

[0010] FIG. 3 is a flow diagram illustrating a process performed using a SC controller, according to some examples.

[0011] FIG. 4 is a flow diagram illustrating a process performed using an overvoltage protection (OVP) module.

[0012] FIG. 5 is a block diagram illustrating overvoltage protection performed using a control system, according to some examples.

[0013] FIG. 6 is a block diagram illustrating use of one or more trained machine learning models of a machine learning engine to identify overvoltage protection, according to some examples.

[0014] FIG. 7 is a flow diagram illustrating a process for providing overvoltage protection performed using a control system, according to some examples.

DETAILED DESCRIPTION

[0015] Aspects of the present disclosure are disclosed in the following description and related figures directed to specific embodiments of the disclosure. Those of ordinary skill in the art will recognize that alternate embodiments may be devised without departing from the claims' spirit or scope. Additionally, well-known elements of exemplary embodiments of the disclosure will not be described in detail or will be omitted so as not to obscure the relevant details of the disclosure

[0016] As used herein, the word exemplary means serving as an example, instance, or illustration. The embodiments described herein are not limiting but rather are exemplary only. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the terms embodiments of the disclosure, embodiments, or disclosure do not require that all embodiments include the discussed feature, advantage, or mode of operation.

[0017] Further, many of the embodiments described herein are described in sequences of actions to be performed by, for example, elements of a computing device. It should be recognized by those skilled in the art that specific circuits can perform the various sequence of actions described herein (e.g., application-specific integrated circuits (ASICs)) and/or by program instructions executed by at least one processor. Additionally, the sequence of actions described herein can be embodied entirely within any form of computer-readable storage medium. The execution of the sequence of actions enables the processor to perform the functionality described herein. Thus, the various aspects of the present disclosure may be embodied in several different forms, all of which have been contemplated to be within the scope of the claimed subject matter. In addition, for each of the embodiments described herein, the corresponding form of any such embodiments may be described herein as, for example, a computer configured to perform the described action.

[0018] Disclosed herein are systems and methods for overvoltage protection. A system, such as a vehicle, for overvoltage protection of a supercapacitor system for an electric vehicle, the system includes a plurality of supercapacitor groups, each supercapacitor group comprising two or more of the plurality of supercapacitors. The system includes a plurality of overvoltage protector units, each the plurality of overvoltage protector units operable to detect the voltage of each of the two or more supercapacitors within the respective one of the supercapacitor groups. The system includes a controller comprising a processor with access to a memory, wherein the control system is operable to determine which of the plurality of supercapacitor groups to connect to the electric vehicle based on data sent from the respective overvoltage protector units.

Energy Storage Unit (ESU):

[0019] The ESU is a device that can store and deliver charge. It may comprise one or more power packs, which may comprise supercapacitors. The energy storage module may also comprise batteries, hybrid systems, fuel cells, etc. Capacitance provided in the components of the ESU may be in the form of electrostatic capacitance, pseudocapacitance, electrolytic capacitance, electronic double-layer capacitance, and electrochemical capacitance, and a combination thereof, such as both electrostatic double-layer capacitance and electrochemical pseudocapacitance, as may occur in supercapacitors. The ESU may be associated with or comprise control hardware and software with suitable sensors, as needed, for an energy control system (ECS) to manage any of the following: temperature control, discharging of the ESU whether collectively or of any of its components, charging of the ESU whether collectively or of any of its components, maintenance, interaction with batteries, battery emulation, communication with other devices, including devices that are directly connected, adjacent, or remotely such as by wireless communication, etc. In some aspects, the ESU may be portable and provided in a casing containing at least some components of the energy control system (ECS) and features such as communication systems, a display interface, etc.

[0020] The term supercapacitor as used herein can also refer to an ultracapacitor, which is an electrical component capable of holding hundreds of times more electrical charge quantity than a standard capacitor. This characteristic makes ultracapacitors useful in devices that require relatively little current and low voltage. In some situations, an ultracapacitor can take the place of a rechargeable low-voltage electrochemical battery. In some examples, the terms supercapacitor or ultracapacitor as used herein can also refer to other types of capacitors.

Energy Control System (ECS)

[0021] The energy control system (ECS) combines hardware and software that manages various aspects of the ESU, including its energy to the device. The ECS regulates the energy storage unit (ESU) to control discharging, charging, and other features as desired, such as temperature, safety, efficiency, etc. The ESU may be adapted to give the ECS individual control over each power pack or optionally over each supercapacitor or grouped supercapacitor unit to tap the available power of individual supercapacitors efficiently and to properly charge individual supercapacitors rather than merely providing a single level of charge for the ESU as a whole that may be too little or too much for individual supercapacitors or their power packs.

[0022] The ECS may comprise or be operatively associated with a processor, a memory comprising code for the controller, a database, and communication tools such as a bus or wireless capabilities for interacting with an interface or other elements or otherwise providing information, information requests, or commands. The ECS may interact with individual power packs or supercapacitors through a crosspoint switch or other matrix systems. Further, the ECS may obtain information from individual power packs or their supercapacitors through similar switching mechanisms or direct wiring in which, for example, one or more of a voltage detection circuit, an amperage detection circuit, a temperature sensor, and other sensors or devices may be used to provide details on the level of charge and performance of the individual power pack or supercapacitor. [0023] The ECS may comprise one or more modules that the processor can execute or govern according to code stored in a memory such as a chip, a hard drive, a cloud-based source, or another computer-readable medium.

[0024] The ECS may therefore manage any or all of the following: temperature control, discharging of the ESU whether collectively or of any of its components, charging of the ESU whether collectively or of any of its components, maintenance, interaction with batteries, or battery emulation, and communication with other devices, including devices that are directly connected, adjacent, or remotely such as by wireless communication.

[0025] The ECS may comprise one or more energy source modules that govern specific energy storage devices, such as a supercapacitor module for governing supercapacitors and a lithium module for governing lithium batteries. A lead-acid module for governing lead-acid batteries and a hybrid module for governing the combined cooperative use of a supercapacitor and a battery. Each of the energy storage modules may comprise software encoding algorithms for control such as for discharge or charging or managing individual energy sources, and may comprise or be operationally associated with hardware for redistributing charge among the energy sources to improve the efficiency of the ESU, for monitoring charge via charge measurement systems such as circuits for determining the charge state of the respective energy sources, etc., and may comprise or be operationally associated with devices for receiving and sending information to and from the ECS or its other modules, etc. The energy source modules may also cooperate with a charging module responsible for guiding the charging of the overall ESU to ensure a properly balanced charge and a discharge module that guides the efficient discharging of the ESU during use which may also seek to provide proper balance in the discharging of the energy sources.

[0026] The ECS may further comprise a dynamic module for managing changing requirements in power supplied. In some aspects, the dynamic module comprises anticipatory algorithms that seek to predict upcoming changes in power demand and adjust the state of the ECS to be ready to handle the change more effectively. For example, in one case, the ECS may communicate with a GPS and terrain map for the route being taken by the electric vehicle and recognize that a steep hill will soon be encountered. The ECS may anticipate the need to increase torque and thus the delivered electrical power from the ESU and thus activate additional power packs if only some are in use or otherwise increase the draw from the power packs to handle the change in slope efficiently to achieve desired objectives such as maintaining speed, reducing the need to shift gears on a hill, or reducing the risk of stalling or other problems.

[0027] The ECS may also comprise a communication module and an associated configuration system to properly configure the ECS to communicate with the interface or other aspects of the vehicle and communicate with central systems or other vehicles when desired. In such cases, a fleet of vehicles may be effectively monitored and managed to improve energy efficiency and track the performance of vehicles and their ESUs, thereby providing information that may assist with maintenance protocols. Such communication may occur wirelessly or through the cloud via a network interface, share information with various central databases, or access information from databases to assist with the vehicle's operation and the optimization of the ESU, for which historical data may be available in a database.

[0028] Databases of use with the ECS include databases on the charge and discharge behavior of the energy sources in the ESU to optimize both charging and discharging in use based on known characteristics, databases of topographical and other information for a route to be taken by the electric vehicle or an operation to be performed by another device employing the ESU, wherein the database provides guidance on what power demands are to be expected in advance to support anticipatory power management wherein the status of energy sources. The available charge is prepared in time to deliver the needed power proactively. Charging databases may also help describe the characteristics of an external power source used to charge the ESU. The external charge characteristics can prepare for impedance matching or other measures needed to handle a new input source to charge the ESU. With that data, the external power can be received with reduced losses and reduced risk of damaging elements in the ESU by overcharge, an excessive ripple in the current, etc.

[0029] Beyond relying on static information in databases, in some aspects, the controller is adapted to perform machine learning and to leam from situations faced constantly. In related aspects, the processor and the associated software form a “smart” controller based on machine learning or artificial intelligence adapted to handle a wide range of input and a wide range of operational demands. ESU Hardware

Charging and Discharging Hardware

[0030] The charging and discharging hardware comprises the wiring, switches, charge detection circuits, current detection circuits, and other devices for proper control of charge applied to the power packs or the batteries or other energy storage units and temperature-control devices such as active cooling equipment and other safety devices. Active cooling devices (not shown) may include fans, circulating heat transfer fluids that pass through tubing or, in some cases, surround or immerse the power packs, thermoelectric cooling such as Peltier effect coolers, etc.

[0031] To charge and discharge an individual unit among the power packs to optimize the overall efficiency of the ESU, methods are needed to select one or more of many units from what may be a three-dimensional or two-dimensional array of connectors to the individual units. Any suitable methods and devices may be used for such operations, including crosspoint switches or other matrix switching tools. Crosspoint switches and matrix switches are means of selectively connecting specific lines among many possibilities, such as an array of X lines (XI, X2, X3, etc.) and an array of Y lines (Yl, Y2, Y3, etc.) that may respectively have access to the negative or positive electrodes or terminals of the individual units among the power packs as well as the batteries or other energy storage units. SPST (Single-Pole Single-Throw) relays, for example, may be used. By applying a charge to individual supercapacitors within power packs or to individual power packs within the ESU, a charge can be applied directly to where it is needed, and a supercapacitor or power pack can be charged to an optimum level independently of other power packs or supercapacitors.

Configuration Hardware

[0032] The configuration hardware comprises the switches, wiring, and other devices to transform the electrical configuration of the power packs between series and parallel configurations, such as that a matrix of power packs may be configured to be in series, in parallel, or some combination thereof. For example, a 12 x 6 array of power packs may have four groups in series, with each group having 3 x 6 power packs in parallel. A command can modify the configuration from the configuration module, which then causes the configuration hardware to make the change at an appropriate time (e.g., when the device is not in use). Sensors

[0033] The sensors may include thermocouples, thermistors, or other devices associated with temperature measurement such as IR cameras, etc., as well as strain gauges, pressure gauges, load cells, accelerometers, inclinometers, velocimeters, chemical sensors, photoelectric cells, cameras, etc., that can measure the status of the power packs or batteries or other energy storage units or other characteristics of the ESU or the device as described more fully hereafter. The sensors may comprise sensors physically contained in or on the ESU or sensors mounted elsewhere, such as engine gauges in electronic communication with the ECS or its associated ESC.

Batteries and Other Energy Sources

[0034] The ESU may be capable of charging or supplementing the power provided from the batteries or other energy storage units, including chemical and nonchemical batteries, such as but not limited to lithium batteries (including those with titanate, cobalt oxide, iron phosphate, iron disulfide, carbon monofluoride, manganese dioxide or oxide, nickel cobalt aluminum oxides, nickel manganese cobalt oxide, etc.), lead-acid batteries, alkaline or rechargeable alkaline batteries, nickel-cadmium batteries, nickel-zinc batteries, nickel-iron batteries, nickel-hydrogen batteries, nickel-metal-hydride batteries, zinc-carbon batteries, mercury cell batteries, silver oxide batteries, sodium-sulfur batteries, redox flow batteries, supercapacitor batteries, and combinations or hybrids thereof.

Power Input/Output Interface

[0035] The ESU also comprises or is associated with a power input/output interface 152 that can receive charge from a device (or a plurality of devices in some cases) such as the grid or regenerative power sources in an electric vehicle (not shown) and can deliver charge to a device such as an electric vehicle (not shown). The power input/output interface may comprise one or more inverters, charge converters, or other circuits and devices to convert the current to the proper type (e.g., AC or DC) and voltage or amperage for either supplying power to or receiving power from the device it is connected to. Bidirectional DC-DC converters may also be applied.

[0036] The power input/output interface may be adapted to receive power from various power sources, such as via two-phase or three-phase power, DC power, etc. It may receive or provide power by wires, inductively, or other proper means. Converters, transformers, rectifiers, and the like may be employed as needed. The power received may be relatively steady from the grid or other sources at voltages such as 110V, 120V, 220V, 240V, etc., or from highly variable sources such as solar or wind power amperage or voltage vary. DC sources may be, by way of example, from IV to 0V or higher, such as from 4V to 200V, 5V to 120V, 6V to V, 2V to 50V, 3V to 24V, or nominal voltages of about 4, 6, 12, 18, 24, 30, or 48 V. Similar ranges may apply to AC sources, but also including from 60V to 300V, from 90V to 250V, from V to 240 V, etc., operating at any proper frequency such as 50 Hz, 60Hz, etc.

[0037] Power received or delivered may be modulated, converted, smoothed, rectified, or transformed in any useful way to better meet the application's needs and the requirements of the device and the ESU. For example, pulse-width modulation (PWM), sometimes called pulseduration modulation (PDM), may be used to reduce the average power delivered by an electrical signal as it is effectively chopped into discrete parts. Likewise, maximum power point tracking (MPPT) may be employed to keep the load at the right level for the most efficient power transfer.

[0038] The power input/out interface may have a plurality of receptacles of receiving power and a plurality of outlets for providing power to one or more devices. Conventional AC outlets may include any known outlet standard in North America, various parts of Europe, China, Hong Kong, etc.

Energy Control System (ECS)

[0039] The energy storage unit (ESU) is governed or controlled by a novel energy control system (ECS) adapted to optimize at least one of charging, discharging, temperature management, safety, security, maintenance, and anticipatory power delivery. The ECS may communicate with a user interface such as a display interface to assist in control or monitoring of the ESU and also may comprise a processor and a memory. The ECS may interact with the ESU’s hardware, such as the charging/discharging hardware and a temperature control system that provides data to the ECS and responds to directions from the ECS to manage the ESU.

[0040] The energy control system (ECS) may comprise a processor, a memory, one or more energy source modules, a charge/discharge module, a communication module, a configuration module, a dynamic module, an identifier module, a security module, a safety module, a maintenance module, and a performance module. ECS Components and Modules

Processor

[0041] The processor may comprise one or more microchips or other systems for executing electronic instructions and can provide instructions to regulate the charging and discharging hardware and, when applicable, the configuration hardware or other aspects of the ESU and other aspects of the ECS and its interactions with the device, the cloud, etc. In some cases, a plurality of processors may collaborate, including processors installed with the ESU and processors installed in a vehicle or other device.

Memory

[0042] The memory may comprise coding to operate one or more of the ECS and their interactions with other components. It may also comprise information such as databases on any aspect of the operation of the ECS, though additional databases are also available via the cloud. Such databases can include a charging database that describes the charging and discharging characteristics of a plurality or all energy sources (the power packs and the batteries or other energy storage units ) to guide charging and discharging operations. Such data may also be included with energy-source-specific data provided by or accessed by the energy source modules.

[0043] The memory may be in one or more locations or components such as a memory chip, a hard drive, a cloud-based source, or another computer-readable medium, and maybe in any application form such as flash memory, EPROM, EEPROM, PROM, MROM, etc., or combinations thereof and consolidated (centralized) or distributed forms. The memory may, in whole or part, be a read-only memory (ROM) or random-access memory (RAM), including static RAM (SRAM), dynamic RAM (DRAM), synchronous dynamic RAM (SDRAM), and magnetoresistive RAM (MRAM), etc.

Cloud Resources

[0044] The ECS may communicate with other entities via the cloud or other means. Such communication may involve information received from and provided to one or more databases and a message center. The message center can provide alerts to an administrator responsible for the ESU and the electric vehicle or another device. For example, an entity may own a fleet of electric vehicles using ESUs and may wish to receive notifications regarding usage, performance, maintenance issues, and so forth. The message center may also authenticate the ESU or verify its authorization for use in the electric vehicle or other devices (not shown) via interaction with the security module.

Energy Source Modules

[0045] The energy source modules may comprise specific modules designed to operate a specific energy source, such as a supercapacitor module, a lithium battery module, a lead-acid battery module, or other modules. Such modules may be associated with a database of performance characteristics (e.g., charge and discharge curves, safety restrictions regarding overcharge, temperature, etc.) that may provide information for use by the safety module and the charge/discharge module, which is used to optimize how each unit within the power packs or batteries or other energy storage units is used both in terms of charging and delivering charge. The charge/discharge module seeks to provide useful work from as much of the charge as possible in the individual power packs while ensuring that individual power packs are fully charged but not damaged by overcharging. The charge/discharge module can assist in directing the charging/discharging hardware, cooperating with the energy source modules. In one aspect, the ESU thus may provide real-time charging and discharging of the plurality of power packs while the electric vehicle is continuously accelerating and decelerating along a path.

Charge/Discharge Module

[0046] The charge/discharge module is used to optimize each unit within the power packs, batteries, or other energy storage units to charge and deliver charge. The charge/discharge module seeks to provide useful work from as much of the charge as possible in the individual power packs while ensuring during charging that individual power packs are fully charged but not damaged by overcharging. The charge/discharge module can assist in directing the charging/discharging hardware, cooperating with the energy source modules. In one aspect, the ESU thus may provide real-time charging and discharging of the plurality of power packs while the electric vehicle is continuously accelerating and decelerating along a path.

[0047] The charge/discharge module may be configured to charge or discharge each of the plurality of power packs up to a threshold limit. The charge/discharge module may be coupled to the performance, energy storage, and identifier modules. It may communicate with the charging/discharging hardware of the ESU. For example, the threshold limit may be more than 90 percent capacity of each of the plurality of power packs in one aspect.

Dynamic Module

[0048] The dynamic module assists in coping with changes in operation, including acceleration, deceleration, stops, changes in slops (uphill or downhill), changes in traction or properties of the road or ground that affect traction and performance, etc., by optimizing the delivery of power or the charging that is taking place for individual power packs or batteries or other energy storage units. In addition to guiding the degree of power provided by or to individual power packs based on the current use of the device and the individual state of the power packs, in some aspects, the dynamic module provides anticipatory management of the ESU by proactively adjusting the charging or discharging states of the power packs such that added power is available as the need arises or slightly in advance (depending on time constants for the ESU and its components, anticipatory changes in status may only be needed for a few seconds (e.g., 5 seconds or less or 2 seconds or less) or perhaps only for 1 second or less such as for 0.5 seconds or less. Still, more extended preparatory changes may be needed in other cases, such as from 3 seconds to 10 seconds, to ensure that adequate power is available when needed but that power is not wasted by changing the power delivery state prematurely. This anticipatory control can involve increasing the current or voltage being delivered. Still, it can also involve increasing the cooling provided by the cooling hardware of the charging and discharging hardware in cooperation with the safety module and when suitable with the charge/discharge module.

[0049] The dynamic module may be communicatively coupled to the charge/discharge module. The dynamic module may be configured to determine the charging and discharging status of the plurality of power packs and batteries or other energy storage units in real-time. For example, in one aspect, the dynamic module may help govern bidirectional charge/discharge in real-time. The electric charge may flow from the ESU into the plurality of power packs and batteries or other energy storage units or vice versa.

Configuration Module

[0050] The ECS may comprise a configuration module configured to determine any change in the configuration of charged power packs from the charging module. For example, in one aspect, the configuration module may be provided to charge the configuration of the power packs, such as from series to parallel or vice versa. This may occur via communication with the charging/discharging hardware of the ESU.

Identifier Module

[0051] The identifier module, described in more detail hereafter, identifies the charging or discharging requirement for each power pack to assist in best meeting the power supply needs of the device. This process may require access to the database information about the individual power packs from the energy source modules (e.g., a supercapacitor module) and information about the current state of the individual power packs provided by the sensors and charge and current detections circuits associated with the charging and discharging hardware, cooperating with the charge/discharge module and, as needed, with the dynamic module and the safety module.

Safety Module

[0052] The sensors may communicate with the safety module to determine if the power packs and individual components show excessive local or system temperature signs that might harm the components. In such cases, the safety module interacts with the processor and other features (e.g., data stored in the databases of the cloud or memory pertaining to safe temperature characteristics for the ESU ) to cause a change in operation such as decreasing the charging or discharging underway with the portions of the power packs or other units facing excessive temperature. The safety module may also regulate cooling systems that are part of the charging and discharging hardware to proactively increase the cooling of the power packs, batteries, or other energy storage units. Increasing the load on them does not lead to harmful temperature increases.

[0053] Thus, the safety module may also interact with the dynamic module in responding to forecasts of system demands in the near future for anticipatory control of the ESU for optimized power delivery. In the interaction with the dynamic module, the safety module may determine that an upcoming episode of high system demand such as imminent climbing of a hill may impose excessive demands on a power pack already operating at elevated temperature, and thus make a proactive recommendation to increase cooling on the at-risk power packs. Other sensors such as strain gauges, pressure gauges, chemical sensors, etc., may be provided to determine if any of the energy storage units in batteries or other energy storage units or the power packs are facing pressure buildup from outgassing, decomposition, corrosion, electrical shorts, unwanted chemical reactions such as an incipient runaway reaction, or other system difficulties. In such cases, the safety module may initiate precautionary or emergency procedures such as a shutdown, electrical isolation of the affected components, warnings to a system administrator via the communication module to the message center, a request for maintenance to the maintenance module.

Maintenance Module

[0054] The maintenance module determines when the ESU requires maintenance, either per a predetermined scheduled or when needed due to apparent problems in performance, as may be flagged by the performance module, or in issues about safety as determined by the safety module based on data from sensors or the charging/discharging hardware, and in light of information from the energy sources modules. The maintenance module may cooperate with the communication module to provide relevant information to the display interface and the message center. An administrator or owner may initiate maintenance action in response to the message provided. The maintenance module may also initiate mitigating actions to be taken, such as cooperating with the charge/discharge module to decrease the demand on one or more of the power packs in need of maintenance and may also cooperate with the configuration module to reconfigure the power packs to reduce the demand in components that may be malfunctioning of near to malfunctioning to reduce harm and risk.

Performance Module

[0055] The performance module continually monitors the results obtained with individual power packs and the batteries or other energy storage units and stores information as needed in memory and the cloud databases or via messages to the message center. The monitoring is done using the sensors and the charging/discharging hardware, etc. The tracking of performance attributes of the respective energy sources can guide knowledge about the system's health, the capabilities of the components, etc., which can guide decisions about charging and discharging in cooperation with the charge/discharge module. The performance module compares actual performance, such as power density, charge density, time to charge, thermal behavior, etc., to specifications and can then cooperate with the maintenance module to help determine if maintenance or replacement is needed and alert an administrator via the communication module with a message to the message center about apparent problems in product quality. Security Module: Security and Anti-Counterfeiting Measures

[0056] The security module helps reduce the risk of counterfeit products or theft or misuse of legitimate products associated with the ESU, thus including one or more methods for authenticating the nature of the ESU and authorization to use it with the device in question. Methods of reducing the risk of theft or unauthorized use of an ESU or its respective power packs can include locks integrated with the casing of the ESU that mechanically secure the ESU in the electric vehicle or other devices, wherein a key, a unique fob, a biometric signal such as a fingerprint or voice recognition system, or other security-related credentials or may be required to enable removal of the ESU or even operation thereof.

[0057] In another aspect, the ESU comprises a unique identifier (not shown) that can be tracked, allowing a security system to verify that a given ESU is authorized for use with the device, such as an electric vehicle or other devices. For example, the casing of the ESU or one or more power packs therein may have a unique identifier attached, such as an RFID tag with a serial number (an active or passive tag), a holographic tag with unique characteristics equivalent to a serial number or password, nanoparticle markings that convey a unique signal, etc. One good security tool that may be adapted for the security of the ESU is a seemingly ordinary bar code or QR code with unique characteristics not visible to the human eye that cannot be readily copied, is the Unisecure™ technology offered by Systech (Princeton, NJ), a subsidiary of Markem-Image, that essentially allows ordinary QR codes and barcodes to become unique, individual codes by analysis of tiny imperfections in the printing to uniquely and robustly identify every individual product, even if it seems that the same code is printed on every one.

[0058] Yet another approach relies at least in part on the unique electronic signature of the ESU and one or more individual power packs or of one or more supercapacitor units therein. The principle will be described relative to an individual power pack but may be adapted to an individual supercapacitor or collectively to the ESU as a whole. When a power pack comprising supercapacitors is charged from a low voltage or relatively discharged state, the electronic response to a given applied voltage depends on many parameters, including microscopic details of the electrode structure such as porosity, pore size distribution, and distribution of coating materials, or details of electrolyte properties, supercapacitor geometry, etc., as well as macroscopic properties such as temperature. At a specified temperature or temperature range and under other suitable macroscopic conditions (e.g., low vibration, etc.), the characteristics of the power pack may then be tested using any suitable tool capable of identifying a signature specific to the individual power pack.

Communication Module

[0059] The communication module can govern communications between the ECS and the outside world, including communications through the cloud, such as making queries and receiving data from various external databases or sending messages to a message center where they may be processed and archived by an administrator, a device owner, the device user, the ESU owner, or automated systems. In some aspects, the communication module may also oversee communication between modules or between the ESU and the ECS and work in cooperation with various modules to direct information to and from the display interface. Communications within a vehicle or between the ECS or ESU and the device may involve a DC bus or other means such as separate wiring. Any suitable protocol may be used, including UART, LIN (or DC-LIN), CAN, SPI, I2C (including Intel’s SMBus), and DMX (e.g., DMX512). In general, communications from the ECS or ESU with a device may be over a DC bus or, if needed, over an AC/DC bus, or by separately wired pathways if desired, or wireless.

[0060] Communication to the cloud may occur via the communication module and involve wired or wireless connections. If wireless, various communication techniques may be employed such as Visible Light Communication (VLC), Worldwide Interoperability for Microwave Access (WiMAX), Long Term Evolution (LTE), Wireless Local Area Network (WLAN), Infrared (IR) communication, Public Switched Telephone Network (PSTN), Radio waves, and other communication techniques.

Electrostatic Module

[0061] Assessment of charge in an energy storage unit can be conducted based on measurements made with the charging/discharging hardware in communication with specific modules of the ECS. In general, an electrostatic module can manage the measurement of charge and processing of the data.

[0062] The electrostatic module may be configured to identify the power pack type and the capacity of each power pack connected to the modular multi-type power pack energy storage unit. Further, the electrostatic module may be configured to retrieve information related to the type of power packs from the charging database. The electrostatic module may determine the capacity of each power pack to be charged. It may be configured to determine the capacity of each power pack when connected to the modular multi-type power pack ESU.

[0063] The electrostatic module may be configured to determine if each power pack charged below the threshold limit. For example, in one aspect, the electrostatic module may check whether each of the plurality of power packs may have a capacity below the threshold limit. The electrostatic module may also be configured to send data related to power packs to the ECS.

Various Databases

[0064] The ECS may access various databases via an interface to the cloud and store retrieved information in the memory to guide the various modules.

[0065] Further, the memory may comprise a charging database or information from such a database obtained from the databases or the cloud. In one aspect, the charging database may be configured to store information related to various power packs used while charging and discharging from the ESU. In one aspect, the charging database may be configured to store information related to the power cycle of each of the plurality of power packs, the maximum and minimum charge for different types of power packs, and the state of charge (SoC) profile of each of the plurality of power packs.

[0066] The charging database may be configured to store information related to managing the plurality of power packs, such as the type of power pack to be charged, safety specifications, recent performance data, bidirectional charging requirements, or history of each of the plurality of power packs, etc. In another aspect, the stored information may also include, but is not limited to, the capacity of each of the plurality of power packs, amount of charge required for one trip of the electric vehicle along the path, such as golf course, etc., charging required for a supercapacitor unit, etc. In another aspect, the charging database may provide a detailed research report for the electric vehicle’s average electric charge consumption over a path. In one aspect, the charging database may be configured to store information of the consumption of the electric charge per unit per kilometer drive of the electric vehicle from the plurality of power packs. For example, such information may indicate that a golf cart is equipped with five supercapacitor-driven power packs each at 90% charge, with each power packable to supply a specified amount of ampere-hours (Ah) of electric charge resulting in an ability to drive under normal conditions at top speed for, say, 80 kilometers. The information may also indicate that a solar cell installed on the roof of the golf cart would, under current partly clouded conditions, still provide enough additional charge over the planned period of use to extend the capacity of the ESU by another 40 kilometers for one passenger.

[0067] The performance module may use the charging database to read data and store new data on the individual energy storage units such as the power packs.

Power Pack

[0068] A power pack is a unit that can store and deliver charge within an energy storage unit and comprises one or more supercapacitors such as supercapacitors in series and parallel. It may further comprise or cooperate with temperature sensors, charge and current sensors (circuits or other devices), connectors, switches such as crosspoint switches, safety devices, and control systems such as charge and discharge control systems. In various aspects described herein, the power pack may comprise a plurality of supercapacitors and have an energy density greater than 200 kWhr/kg, 230 kWhr/kg, 260 kWhr/kg, or 300 kWhr/kg, such as from 200 to 500 kWhr/kg, or from 250 to 500 kWhr/kg. The power pack may have a functional temperature range from -70°C to +°C, such as from -50°C to °C or from -40°C to 80°C. The voltage provided by the power pack may be any practical value such as 3 V or more significant, such as from 3 V to 240 V, 4V to 120 V, etc.

[0069] By way of example, a power pack may comprise one or more units, each comprising at least one supercapacitor having a nominal voltage from 2 to 12 V, such as from 3 to 6 V, including supercapacitors rated at about 3, 3.5, 4, 4.2, 4.5, and 5 V. For example, in discharge testing, a power pack was provided and tested with 14 capacitors in series and five series in parallel charged with 21,000F at 4.2 V and had 68-75Wh. Power packs may be packaged in protective casings that can easily be removed from an ESU and replaced. They may also comprise connectors for charging and discharging. Power packs may be provided with generally rectilinear casings, or they may have cylindrical or other useful shapes. Supercapacitor Information

Supercapacitors

[0070] A supercapacitor may have two electrode layers separated by an electrode separator wherein each electrode layer is electrically connected to a current collector supported upon an inert substrate layer; further comprising an electrolyte-impervious layer disposed between each electrode layer and each conducting layer to protect the conducting layer, and a liquid electrolyte disposed within the area occupied by the active electrode layers and the electrode separator. To inhibit electrolyte flow, the liquid electrolyte may be an ionic liquid electrolyte gelled by a silica gellant or other gellant.

[0071] The supercapacitor may comprise an electrode plate, an isolation film, a pole, and a shell. The electrode plate comprises a current collector, and a coating is disposed of on the current collector. The coating may comprise an active material that may include carbon nanomaterial such as graphene or carbon nanotubes, including nitrogen-doped graphene, a carbon nitride, carbon materials doped with a sulfur compound such as thiophene or poly 3 -hexylthiophene, etc., or graphene on which is deposited nanoparticles of metal oxide such as manganese dioxide. The coating may further comprise a conductive polymer such as one or more polyaniline, polythiophene, and polypyrrole. Such polymers may be doped with various substances such as boron (especially in the case of polyaniline).

[0072] Electrodes in supercapacitors may have thin coatings in electrical communication with a current collector, to provide high electrode surface area for high performance, electrodes may comprise porous material with a high specific surface area such as graphene, graphene oxide, or various derivatives of graphene, carbon nanotubes or other carbon nanomaterials including activated carbon, nitrogen-doped graphene or another doped graphene, graphite, carbon fibercloth, carbide-derived carbon, carbon aerogel. They may comprise various metal oxides such as oxides of manganese, etc. All such materials may be provided in multiple layers and generally planar, cylindrical, or other geometries. Electrolytes in the supercapacitor may include semi-solid or gel electrolytes, conductive polymers or gels thereof, ionic liquids, aqueous electrolytes, and the like. Solid-state supercapacitors may be used. [0073] Supercapacitors may be provided with various indicators and sensors about charge state, temperature, and other performance and safety aspects. An actuation mechanism may be integrated to prevent undesired discharge.

[0074] The voltage of an individual supercapacitor may be greater than 2 V, such as from 2.5 V to 5 V, 2.7 V to 8 V, 2.5 V to 4.5 V, etc.

[0075] Supercapacitors can be divided into units of smaller supercapacitors. In one embodiment, a “constant voltage unit” of five units can be joined together in parallel to maintain the voltage but supply five times more current. In another embodiment, a “constant current unity” can include five units joined together in series to multiply the unit voltage by five times but maintain the current. In another embodiment, supercapacitors can provide hybrid “constant voltage units” and “constant current units.” In yet another embodiment, supercapacitors units can be connected in any number of combinations to end up with a supercapacitor of optimum design. In another embodiment, each supercapacitor unit can comprise various subunits or pouches. Supercapacitor subunits can be combined using constant current, voltage, or any combination. Supercapacitor units or sub-units can comprise size or form factors in yet another embodiment. In yet another embodiment, each subunit and unit can be uniquely addressed to turn on or off the supercapacitor unit or sub-unit on or off This is achieved with any variety of crossbar switches. A crossbar switch is an assembly of individual switches between inputs and a set of outputs. The switches are arranged in a matrix. If the crossbar switch has M inputs and N outputs, then a crossbar has a matrix with M x N cross- points or places where the connections cross. At each crosspoint is a switch; when closed, it connects one of the inputs to one of the outputs. A given crossbar is a single layer, non-blocking switch. A non-blocking switch means that other concurrent connections do not prevent connecting other inputs to other outputs. Collections of crossbars can be used to implement multiple layers and blocking switches. A crossbar switching system is also called a coordinate switching system. In this way, a crossbar switch can select any combinations of pouches or subunits and units to obtain any combination. The crossbar switches can be used to test units or subunits and optimize supercapacitor performance.

Powered Devices and Electric Vehicles, etc.

[0076] Powered devices powered by the ESU can include electric vehicles and other transportation devices of all kinds, such as those for land, water, or air, whether adapted to operate without passengers or with one or more passengers. Electric vehicles may include automobiles, trucks, vans, forklifts, carts such as golf carts or baby carts, motorcycles, electric bikes scooters, autonomous vehicles, mobile robotic devices, hoverboards, monowheels, Segways® and other personal transportation devices, wheelchairs, drones, personal aircraft for one or more passengers and other aeronautical devices, robotic devices, aquatic devices such as boats or personal watercraft such as boats, Jet Skis®, diver propulsion vehicles or underwater scooters, and the like, etc. The electric vehicle generally comprises one or more motors connected to the ESU and an energy control system (ECS) that controls the power delivered from the ESU and may comprise a user interface that provides information and control regarding the delivery of power from the ESU as well as information regarding performance, remaining charge, safety, maintenance, security, etc. Not all transportation devices require non-stationary motors. An elevator, for example, may have a substantially stationary motor while the cabin moves between the level of a structure. Other transport systems with mobile cabins, seats, or walkways may be driven by stationary motors driving cables, chains, gears, bands, etc.

[0077] Apart from electric vehicles, there are many other devices that the ESU may power in cooperation with the ESC. Such other devices can include generators, which in turn can power an endless list of electric devices in households and industry. ESUs of various sizes and shapes can also be integrated with a variety of motors, portable devices, wearable or implantable sensors, medical devices, acoustic devices such as speakers or noise cancellation devices, satellites, robotics, heating and cooling devices, lighting systems, rechargeable food processing tools and systems of all kinds, personal protection tools such as tasers, lighting and heating systems, power tools, computers, phones, tablets, electric games, etc. In some versions, the powered device is the grid, and in such versions, the ESU may comprise an inverter to turn DC into AC suitable for the grid.

[0078] In some aspects, a plurality of devices such as electric vehicles may be networked together via a cloud-based network, wherein the devices share information among themselves and with a central message center such that an administrator can assist in managing the allocation of resources, oversee maintenance, evaluate the performance of vehicles and ESUs, upgrade software or firmware associated with the ESC to enhance performance for the particular needs of individual users or a collective group, adjust operational settings to better cope with anticipated changes in weather, traffic conditions, etc., or otherwise optimize performance. Implementation in hybrid vehicles

[0079] When installed in electric vehicles, the ESU may comprise both power packs and one or more lead-acid batteries or other batteries. The ESU may power both the motor and the onboard power supply system. The display interface of the associated ESC may comprise a graphical user interface such as the vehicle’s control panel (e.g., a touch panel). The display interface may also comprise audio information and verbal input from a user.

Motors

[0080] The ESU may power any electric motor. The major classes of electric motors are: 1) DC motors, such as series, shunt, compound wound, separately excited (wherein the connection of stator and rotor is made using a different power supply for each), brushless, and PMDC (permanent magnet DC) motors, 2) AC motors such as synchronous, asynchronous, and induction motors (sometimes also called asynchronous motors), and 3) special purpose motors such as servo, stepper, linear induction, hysteresis, universal (a series-wound electric motor that can operate on AC and DC power), and reluctance motors.

Display Interface

[0081] The display interface of the ESC may be displayed on or in the device, such as on a touch screen or other display in a vehicle or on the device, or it may be displayed by a separate device such as the user’s phone. The display interface may comprise or be part of a graphic user interface such as the vehicle’s control panel (e.g., a touch panel). The display interface may also comprise audio information and verbal input from a user. It may also be displayed on the ESU itself or a surface connected to or communicated with the ESU. In one version, the display interface may include but is not limited to a video monitoring display, a smartphone, a tablet, and the like, each capable of displaying a variety of parameters and interactive controls. Still, the display could also be as simple as one or more lights indicating charging or discharging status and optionally one or more digital or analog indicators showing remaining useful lifetime, % power remaining, voltage, etc.

[0082] Further, the display interface may be any state-of-the-art display means without departing from the scope of the disclosure. In some aspects, the display interface provides graphical information on charge status, including one or more fractions of charge remaining or consumed, remaining useful life of the ESU or its components (e.g., how many miles of driving or hours of use are possible based on current or projected conditions or based on an estimate of the average conditions for the current trip or period of use), and may also provide one or more user controls to allow selection of settings. Such settings may include low, medium, or high values for efficiency, power, etc.; adjustment of operating voltage when feasible; safety settings (e.g., prepare the ESU for shipping, discharge the ESU, increase active cooling, only apply low power, etc.); planned conditions for use (e.g., outdoors, high-humidity, in the rain, underwater, indoors, etc.). Selections may be made through menus and buttons on a visual display, through audio “display” of information responsive to verbal commands, or through text commands or displays transmitted to a phone or computer, including text messages or visual display via an app or web page.

[0083] Thus, the ESU may comprise a display interface coupled to the processor to continuously display the status of charging and discharging the plurality of power packs.

General:

[0084] All patents and applications cited must be understood as being incorporated by reference to their compatible degree.

[0085] For all ranges given herein, it should be understood that any lower limit may be combined with any upper limit when feasible. Thus, for example, citing a temperature range of from 5°C to °C and from 20°C to 200°C would also inherently include a range of from 5°C to 200°C and a range of 20°C to °C.

[0086] When listing various aspects of the products, methods, or system described herein, it should be understood that any feature, element, or limitation of one aspect, example, or claim may be combined with any other feature, element, or limitation of any other aspect when feasible (i.e., not contradictory). Thus, disclosing an example of a power pack comprising a temperature sensor and then a different example of a power pack associated with an accelerometer would inherently disclose a power pack comprising or associated with an accelerometer and a temperature sensor.

[0087] Unless otherwise indicated, components such as software modules or other modules may be combined into a single module or component or divided. The function involves the cooperation of two or more components or modules. Identifying an operation or feature as a single discrete entity should be understood to include division or combination such that the effect of the identified component is still achieved.

[0088] Some embodiments of this disclosure, illustrating its features, will now be discussed in detail. It can be understood that the embodiments are intended to be open-ended in that an item or items used in the embodiments is not meant to be an exhaustive listing of such items or items or meant to be limited to only the listed item or items.

[0089] It can be noted that as used herein and in the appended claims, the singular forms “a," “an,” and “the” include plural references unless the context clearly dictates otherwise. Although any systems and methods similar or equivalent to those described herein can be used to practice or test embodiments, only some exemplary systems and methods are now described.

[0090] FIG. 1 is a system for a Supercapacitor System with Over Voltage Protection capability. This system comprises SC Adder Module 104, a self-contained unit with 2 connections 126. SC Adder Module 104 has a higher capacity than electrochemical batteries as they deliver adequate charges at a much smaller weight and size. SC Adder Module 104 comprises Supercapacitor batteries (SC Batteries 112) and contains a control system to connect to Electric Vehicle 120 and manage charging. SC Adder Module 104 uses SC Controller 116 to switch in and out the SC batteries 112 to Electric Vehicle 120 as needed. The SC Adder module contains a memory 114 and a base module 108. Also, SC Adder Module 104 runs OVP Module 130 continually. SC Adder Module 104 has a database 118 that stores and uses all relevant information to the OVP Module 130 and the Charger Module 128. SC Adder Module has controller 110 that executes instructions from Memory 114. SC Adder Module 104 has Over Voltage Protection HDWR 132 and Testing HDWR 134. Further, Base Module 108 switches on Path 1 122, using SC Controller 116 to connect SC battery 112 thru Overvoltage Protection 132 circuits to Electric Vehicle 120. Base Module 108 executes OVP Module 130. Base Module 108 reads Database 118 OVP data, and if "OVP error" is found, stop Base Module 108. Base Module 108 reads Database 118 OVP data, and if "SC Battery Needs Charging" is found, then trigger charge needed to display (not shown). Further, Controller 110 is a processor to execute commands in memory 114 from Base Module 108, allows access (reading and writing the database 118 and allows instruction to turn on and off SC Controller 116. Controller 110 also allows for current measurements from path 1 to be collected and stored (in real-time) in database 118. Controller 110 also controls the switching of the high- powered switching relay in path 1 as base module 108 executes. SC Batteries 112 are any type or group of Supercapacitor batteries designed to have enough capacity to run Electric Vehicle 120. SC Batteries 112 comprises "pouch subunits" where groups of pouch subunits are created. Each pouch subunit group has an overvoltage protection HDWR 132. Each pouch subunit group has a unique addressable location using a cross bar switch matrix (not shown). A crossbar setup is a matrix where each crossbar switch runs between two points in a design intended to hook up each part of an architecture to every other part. Memory 114 is designed to operate the storage of Base Module 108 and its sub-modules and Database 118. Further, SC Controller 116 polls Base Module 108. SC Controller 116 determines if Base Module 108 executes SC Controller Module 116 to switch in or out between the SC Batteries 112 to electric vehicle 120 by path 1 (not shown this is done with a high-powered switching relay). SC Controller 116 determines if Base Module 108 executes SC Controller Module 116 to switch in or out between SC Batteries 112 to connect to Electric Vehicle 120. Database 118 allows reading and writing data from Base Module 108 and their sub-modules and data associated with SC Controller 116. Database 118 stores all the measurements and meta data (errors, etc.) created in OVP Module 130. Electric Vehicle 120 may be any electric vehicle from industrial, recreational, etc.. Path 1 122 shows connections between Electric Vehicle 120 and SC Battery 123, which is interrupted by the insertion of SC Adder Module 104. Connection 126 shows terminals (such as battery terminals) connecting SC Adder Module 104 into the system 100. Further, OVP Module 130 is constantly running connected to SC Batteries 112, Over Voltage Protection HDWR 132, SC Controller 116, and Electric Vehicle 120. OVP Module 130 records change in charge and amperage in database 118. OVP Module 130 assesses, using OVP Module 130 the Over Voltage Protection HDWR 132. OVP Module 130 determines if Over Voltage Protection HDWR 132 is in good status. In some embodiments checking the overvoltage protection 132 circuits of any of the group of supercapacitors, each supercapacitor group can be isolated and tested (using testing HDWR 134) separately by using a crossbar matrix switch (not shown). Suppose the voltage for > 50% of the group's measure is very different than all the other groups, for example, +/-20% different than the average. In that case, it is likely the Over Voltage Protection HDWR 132 circuits are failing. OVP Module 130 writes "OVP Error" in Database 118 and returns to Base Module 108. OVP Module 130 sets up units and subunits of SC Batteries 112 into groups to be used (connected to Electric Vehicle 120) and groups not to be used (held in reserve and not connected to Electric Vehicle 120) using crossbar matrix switch (not shown). Supercapacitor batteries 112 groups must meet a specific voltage and current level to run Electric Vehicle 120. This is achieved by selecting supercapacitor batteries 112 groups connected in series to get to the voltage needed and then adding groups in parallel to the current needed. Many more supercapacitors are needed that remain "unused" and are kept in "storage" for later use. In one embodiment, the chosen groups have close to the same voltage and leakage as determined by filtering the database 118. The data for all groups have been previously measured by testing HDWR 134 (not shown). OVP Module 130 connects the required supercapacitor groups to Electric Vehicle 120 through SC Controller 116 and SC Batteries 112 with connected Over Voltage Protection HDWR 132. OVP Module 130 monitors the charge and voltage of each connected group using Testing HDWR 134, stores all data in database 118. OVP Module 130 reads Database 118 and disconnects any unbalanced groups (if any) of supercapacitors and replaces disconnected groups with the optimum unused groups of supercapacitors, saving all data in database 118. In one embodiment, an unbalanced group. In some embodiments checking the voltage and charge of any of the group of supercapacitors, each supercapacitor group can be isolated and tested (using testing HDWR 134) separately by using a crossbar matrix switch (not shown). If the voltage > 10% of the groups' average is measured, the group of supercapacitors is likely unbalanced. Each unbalanced group is swapped out (using crossbar matrix switch, not shown) for a group in the unused groups that have as close as possible voltage, and that group is swapped in (using crossbar matrix switch not shown). If no more groups are left in the new group, the OVP Module writes, "SC Batteries 112 need a charge," and control returns to Base Module 108. OVP Module 130 loops back. Further, Over Voltage Protection HDWR 132 comprise circuits, such as "plug and play solutions," auto-balancing unit cells such as "ALD's SABMBOVP2XX Printed Circuit Boards". Each supercapacitor pouch has one Over Voltage Protection HDWR 132 circuit. Further, Testing Hardware 134 has the testing devices to test the supercapacitor pouches' voltage, charge, and leakage measurements and determine if Over Voltage Protection HDWR 132 circuits are working normally.

[0091] Functioning of the "Base Module" will now be explained with reference to FIG. 2. One skilled in the art will appreciate that, for this and other processes and methods disclosed herein, the functions performed in the processes and methods may be implemented in differing order. Furthermore, the outlined steps and operations are only provided as examples, and some of the steps and operations may be optional, combined into fewer steps and operations, or expanded into additional steps and operations without detracting from the essence of the disclosed embodiments.

[0092] FIG. 2. is a flow diagram illustrating a process 250 performed using the Base Module 108. The process begins with Base Module 108 switches on Path 1 122, using SC Controller 116 to connect SC battery 112 thru Overvoltage Protection 132 circuits to Electric Vehicle 120, at operation 200. Base Module 108 executes OVP Module 130 at operation 202. Base Module 108 reads Database 118 OVP data, and if "OVP error" is found, stop Base Module 108 at operation 204. Base Module 108 reads Database 118 OVP data, and if "SC Battery Needs Charging" is found, then trigger charge needed to display (not shown) at operation 206.

[0093] Functioning of the "SC Controller" will now be explained with reference to FIG. 3. One skilled in the art will appreciate that, for this and other processes and methods disclosed herein, the functions performed in the processes and methods may be implemented in differing order. Furthermore, the outlined steps and operations are only provided as examples, and some of the steps and operations may be optional, combined into fewer steps and operations, or expanded into additional steps and operations without detracting from the essence of the disclosed embodiments.

[0094] FIG. 3. is a flow diagram illustrating a process 350 performed using the SC Controller 116 operation. The process begins with SC Controller 116 polls Base Module 108, at operation 300. SC Controller 116 determines if Base Module 108 executes SC Controller Module 116 to switch between EC Batteries 102 and SC Batteries 112, then SC Controller 116 disconnects path 1 by instructing switch and test module 106 to disconnect path 1 (not shown this is done with a high powered switching relay) and SC Controller 116 switches SC Batteries 112 onto path 2, using high powered switching relays (not shown) so that Electric Vehicle 120 has power, at operation 302. SC Controller 116 determines if Base Module 108 executes SC Controller Module 116 to switch between SC Batteries 112 and EC Batteries 102. SC Controller 116 disconnects path two using high-powered switching relays (not shown) and then instructs switch and test module 106 to connect pathl (not shown; this is done with a high-powered switching relay). This allows EC Battery 102 onto path 1 so that Electric Vehicle 120 has power at operation 304. SC Controller Module 116 then returns control to Base Module 108 at operation 306.

[0095] Functioning of the "OVP Module" will now be explained with reference to FIG. 4. One skilled in the art will appreciate that, for this and other processes and methods disclosed herein, the functions performed in the processes and methods may be implemented in differing order. Furthermore, the outlined steps and operations are only provided as examples, and some of the steps and operations may be optional, combined into fewer steps and operations, or expanded into additional steps and operations without detracting from the essence of the disclosed embodiments.

[0096] FIG. 4 is a flow diagram illustrating a process 450 performed using the OVP Module 130. The process begins with OVP Module 130 constantly running as it is connected to SC Batteries 112, Over Voltage Protection HDWR 132, SC Controller 116, and Electric Vehicle 120, at operation 400. OVP Module 130 records change in charge and amperage in database 118, at operation 402. OVP Module 130 assesses, using OVP Module 130 the Over Voltage Protection HDWR 132, at operation 404. OVP Module 130 determines if Over Voltage Protection HDWR 132 is in good status. In some embodiments checking the overvoltage protection 132 circuits of any of the group of supercapacitors, each supercapacitor group can be isolated and tested (using testing HDWR 134) separately by using a crossbar matrix switch (not shown). Suppose the voltage for > 50% of the group's measure is very different than all the other groups, for example, +/-20% different than the average. In that case, it is likely the Over Voltage Protection HDWR 132 circuits are failing. OVP Module 130 writes "OVP Error" in Database 118 and returns to Base Module 108 at operation 406. OVP Module 130 sets up units and subunits of SC Batteries 112 into groups to be used (connected to Electric Vehicle 120) and groups not to be used (held in reserve and not connected to Electric Vehicle 120) using crossbar matrix switch (not shown). Supercapacitor batteries 112 groups must meet a specific voltage and current level to run Electric Vehicle 120. This is achieved by selecting supercapacitor batteries 112 groups connected in series to get to the voltage needed and then adding groups in parallel to the current needed. Many more supercpacitors are needed that remain "unused" and are kept in "storage" for later use. In one embodiment, the chosen groups have close to the same voltage and leakage as determined by filtering the database 118. The data for all groups have been previously measured by testing HDWR 134 (not shown) at operation 408. OVP Module 130 connects the required used supercapacitor groups to Electric Vehicle 120 through SC Controller 116 and SC Batteries 112 with connected Over Voltage Protection HDWR 132, at operation 410. OVP Module 130 monitors the charge and voltage of each connected group using Testing HDWR 134, stores all data in database 118. at operation 412. OVP Module 130 reads Database 118 and disconnects any unbalanced groups (if any) of supercapacitors and replaces disconnected groups with the optimum unused groups of supercapacitors, saving all data in database 118. In one embodiment, an unbalanced group. In some embodiments checking the voltage and charge of any of the group of supercapacitors, each supercapacitor group can be isolated and tested (using testing HDWR 134) separately by using a crossbar matrix switch (not shown). If the voltage > 10% of the groups' average is measured, the group of supercapacitors is likely unbalanced. Each unbalanced group is swapped out (using crossbar matrix switch, not shown) for a group in the unused groups that have as close as possible voltage, and that group is swapped in (using crossbar matrix switch not shown). If no more groups are left in the new group, the OVP Module writes, "SC Batteries 112 need a charge," and control returns to Base Module 108, at operation 414. OVP Module 130 returns to operation 412, at operation 416.

[0097] The OVP balancing scheme manages both over-voltage and leakage current. The OVP matches precision push-pull voltage/ current action, which is ideal for cells with a minimal amount of energy loss. Supercapacitors are used for energy storage for electric vehicles. Series-connected supercapacitors may run into issues of voltage imbalance, which could cause “over-voltage” of a cell. Balancing a string of supercapacitors can be done with paralleled resistors, carefully-chosen FETs, or via dynamic stack monitoring

[0098] FIG. 5 is a block diagram illustrating a switch 505 controlled by a controller 506 that toggles between a first configuration in which components 510 draw power from supercapacitor battery 502 and a second configuration in which the components 510 draw power from a supercapacitor battery 504. While supercapacitor batter 502 is only illustrated as a single battery, the supercapacitor battery 1 502 could be a plurality of supercapacitor batteries as described above that form a group of batteries that provide the desired voltage and current. The SC Battery Group 1 could be a completely different set of SC batteries from SC Battery Group 2 or in other examples contain some of the same batteries. The components 510 are components of a vehicle 120, such as a propulsion mechanism (e.g., engine and/or motor and/or other actuator), headlights, windshield wipers, radio, speakers, power brakes, power steering, display, camera, sensors, and the like. The first configuration is illustrated by a dashed line to the left, connecting the SC Battery Group 1 502 to the components 510, and disconnecting the SC Battery Group 2 504 from the components 710. The second configuration is illustrated by a dashed line to the right, connecting the SC Battery Group 2 504 to the components 510, and disconnecting the SC Battery Group 1 502 from the components 510. The toggling of the switch 505 between the two configurations can be controlled by the controller 515, which can be an example of the system 100, the electrochemical battery 102, the SC adder module 104, the switch and test module 106, the SC controller 116, the controller 110, the SC batteries 112, the memory 114, the base module 108, the database 118, electric vehicle 120, or a combination thereof. The switch 505 can be a crossbar switch, a mechanical switch, a Single Pole Single Throw (SPST) switch, a Single Pole Double Throw (SPDT) switch, a Double Pole Single Throw (DPST) switch, a Double Pole Double Throw (DPDT) switch, a toggle switch, a transistor switch, an NPN transistor switch, a PNP transistor switch, an H-bridge switch, or a combination thereof.

[0099] FIG. 6 is a block diagram 800 illustrating use of one or more trained machine learning models 825 of a machine learning engine 820 to identify a power draw 830 and/or an overvoltage protection of a supercapacitor system 835, for instance to prevent the supercapacitors from not performing properly. The ML engine 820 and/or the ML model(s) 825 can include one or more neural network (NNs), one or more convolutional neural networks (CNNs), one or more trained time delay neural networks (TDNNs), one or more deep networks, one or more autoencoders, one or more deep belief nets (DBNs), one or more recurrent neural networks (RNNs), one or more generative adversarial networks (GANs), one or more conditional generative adversarial networks (cGANs), one or more other types of neural networks, one or more trained support vector machines (SVMs), one or more trained random forests (RFs), one or more computer vision systems, one or more deep learning systems, one or more classifiers, one or more transformers, or combinations thereof. Within FIG. 6, a graphic representing the trained ML model(s) 825 illustrates a set of circles connected to another. Each of the circles can represent a node, a neuron, a perceptron, a layer, a portion thereof, or a combination thereof. The circles are arranged in columns. The leftmost column of white circles represent an input layer. The rightmost column of white circles represent an output layer. Two columns of shaded circled between the leftmost column of white circles and the rightmost column of white circles each represent hidden layers. The ML engine 820 and/or the ML model(s) 825 can be part of the AI/ML module.

[0100] Once trained via initial training 865, the one or more ML models 825 receive, as an input, input data 805 that identifies power draw by various components and/or subsystems of a system (e.g., of a vehicle), for instance tracking power draw by various components and/or subsystems of the system (e.g., of the vehicle) over time. In some examples, the input data 805 identifies operations) and/or processes that are performed using the various components and/or subsystems of the system (e.g., of the vehicle) using the tracked power over time. In some examples, the input data 805 identifies attribute(s) of charging and/or discharging and/or capabilities of an energy storage unit (ESU) (e.g., type, voltage, discharge curve, capacitance, impedance, current, amperage, capacity, energy density, specific energy density, power density, temperature, temperature dependence, service life, physical attributes, charge cycle, discharge cycle, cycle life, deep discharge ability, discharge rate, charge rate, and the like), attribute(s) of the components and/or subsystems of the system (e.g., of the vehicle) that draw charge from the ESU, attribute(s) of the system (e.g., of the vehicle) that includes the ESU and draws charge from the ESU (e.g., mileage, efficiency, ergonomics, aerodynamics, shape, geometry, weight, horsepower, brake power, turning radius, type, size, energy consumption rate, location, speed, velocity, acceleration, deceleration, turning radius, and the like), or a combination thereof.

[0101] At least some of the input data 805 may be received from one or more sensors, such as sensors to measure voltage, current, resistance, capacitance, inductance, frequency, power, temperature, continuity, location, motion, acceleration, deceleration, orientation, changes to any of these attributes, or a combination thereof. In some examples, the one or more sensors can include one or more voltmeters, ammeters, ohmmeters, capacimeters, inductance meters, wattmeters, thermometers, thermistors, multimeters, accelerometers, gyrometers, gyroscopes, global navigation satellite system (GNSS) receivers, inertial measurement units (IMUs), or a combination thereof. In some examples, the input data 805 may be received from a one or more databases, such as the database 118, where at least some of the input data 805 may be stored after measurement by the sensors. In some examples, the input data 805 can also include information that is indicative of total capacity of the ESU, the remaining charge and/or remaining capacity of the ESU, a level of shade or shadows that could prevent solar cells from generating charge from light (e.g., whether or not shade or shadows are blocking solar cells to prevent solar charging), a route of the vehicle, a schedule trip of the vehicle, elevation data indicative of uphill and/or downhill portions of a route of the vehicle, or a combination thereof. In some examples, for instance during validation 875, the ML engine 820 and/or the one or more ML models 825 can also receive, as an additional input, a predetermined power draw 840 (e.g., current power draw or predicted future power draw) that is based on (or otherwise corresponds to) the input data 805. In response to receiving at least the input data 805 as an input(s), the one or more ML model(s) 825 estimate the power draw 830 (e.g., current power draw or predicted future power draw) based on the input data 805. In some examples, for instance during validation 875, the ML engine 820 and/or the one or more ML models 825 can also receive, as an additional input, an overvoltage protection 845 (e.g., when the supercapacitor is subject to producing an OVP error as discussed herein) that is based on (or otherwise corresponds to) the input data 805. In response to receiving at least the input data 805 as an input(s), the one or more ML model(s) 825 can estimate the overvoltage protection 835 based on the input data 805. The power draw 830 (e.g., current power draw or predicted future power draw) and overvoltage protection 835 can indicate an amount of power drawn, a rate at which power is drawn, and the like. The power draw and overvoltage protection can each be indicated in terms of voltage, current, resistance, capacitance, inductance, frequency, power, amperage, capacity, energy density, specific energy density, power density, charge cycle, discharge cycle, cycle life, deep discharge ability, discharge rate, charge rate, or a combination thereof. The power draw and overvoltage protection can each be indicated in units of watts, amps, volts, ohms, joules, farads, henries, any of the previously-listed units measured per distance or area (e.g., per meter or per meter squared), any of the previously-listed units measured per unit of time (e.g., per second or per second squared), or a combination thereof.

[0102] Identifying the power draw 830 (e.g., estimated current power draw or predicted future power draw) and/or the overvoltage protection 835 can correspond to at least operations. It should be understood that the pre-determined power draw 840 and/or the pre-determined overvoltage protection 845 can likewise include any of the types of power draw information and/or overvoltage protection information listed above with respect to the power draw 830 and/or the overvoltage protection 835.

[0103] Once the one or more ML models 825 identify the power draw 830 and/or the overvoltage protection 835, the power draw 830 and/or the overvoltage protection 835 can be output to an output interface that can indicate the power draw 830 and/or the overvoltage protection 835 to a user (e.g., by displaying the power draw 830 and/or the overvoltage protection 835 or playing audio indicative of the power draw 830 and/or the overvoltage protection 835) and/or to the energy management system 100 (e.g., the vehicle), which can adjust settings and/or configurations for the energy management system 100 (e.g., the vehicle), for instance to switch (e.g., as in operation 706) between a first configuration in which a first group or groups of supercapacitors are coupled to the vehicle and a second configuration in which a second group or groups of supercapacitors are coupled to the vehicle. [0104] Before using the one or more ML models 825 to identify the power draw 830 and/or the overvoltage protection 835, the ML engine 820 performs initial training 865 of the one or more ML models 825 using training data 870. The training data 870 can include examples of the input data tracking power draw and/or ESU attributes and/or operations over time (e.g., as in the input data 805), examples of a pre-determined power draw (e.g., as in the pre-determined power draw 840), and/or examples of a pre-determined overvoltage protection (e.g., as in the pre-determined overvoltage protection 845). In some examples, the pre-determined power draw in the training data 870 are power draw(s) that the one or more ML models 825 previously identified based on the input data in the training data 870. In some examples, the pre-determined overvoltage protection in the training data 870 are overvoltage protection that the one or more ML models 825 previously identified based on the input data in the training data 870. In the initial training 865, the ML engine 820 can form connections and/or weights based on the training data 870, for instance between nodes of a neural network or another form of neural network. For instance, in the initial training 865, the ML engine 820 can be trained to output the pre-determined power draw and/or the pre-determined overvoltage protection in the training data 870 in response to receipt of the corresponding input data in the training data 870.

[0105] During a validation 875 of the initial training 865 (and/or further training 855), the input data 805 (and/or the exemplary input data in the training data 870) is input into the one or more ML models 825 to identify the power draw 830 and/or the overvoltage protection 835 as described above. The ML engine 820 performs validation 875 at least in part by determining whether the identified power draw 830 and/or the identified overvoltage protection 835 matches the predetermined power draw 840 (and/or the pre-determined power draw in the training data 870) and/or the pre-determined overvoltage protection 845 (and/or the pre-determined overvoltage protection in the training data 870). If, during validation 875, the power draw 830 matches the pre-determined power draw 840 and/or if the overvoltage protection 835 matches the pre-determined overvoltage protection 845, then the ML engine 820 performs further training 855 of the one or more ML models 825 by updating the one or more ML models 825 to reinforce weights and/or connections within the one or more ML models 825 that contributed to the identification of the power draw 830 and/or the overvoltage protection 835, encouraging the one or more ML models 825 to make similar power draw and/or overvoltage protection determinations given similar inputs. If, during validation 875, the power draw 830 and/or the overvoltage protection 835 does not match the pre- determined power draw 840 and/or the pre-determined overvoltage protection 845, then the ML engine 820 performs further training 855 of the one or more ML models 825 by updating the one or more ML models 825 to weaken, remove, and/or replace weights and/or connections within the one or more ML models that contributed to the identification of the power draw 830 and/or the overvoltage protection 835, discouraging the one or more ML models 825 from making similar power draw and/or overvoltage protection determinations given similar inputs.

[0106] Validation 875 and further training 855 of the one or more ML models 825 can continue once the one or more ML models 825 are in use based on feedback 850 received regarding the power draw 830 and/or the overvoltage protection 835. In some examples, the feedback 850 can be received from a user via a user interface, for instance via an input from the user interface that approves or declines use of the power draw 830 and/or the overvoltage protection 835. In some examples, the feedback 850 can be received from another component or subsystem of the vehicle (e.g., an energy control system), for instance based on whether the component or subsystem successfully uses the power draw 830 and/or the overvoltage protection 835, whether use the power draw 830 and/or the overvoltage protection 835 causes any problems for the component or subsystem (e.g., which may be detected using the sensors), whether use the power draw 830 and/or the overvoltage protection 835 are accurate, or a combination thereof. If the feedback 850 is positive (e.g., expresses, indicates, and/or suggests approval of the power draw 830 and/or the overvoltage protection 835, success of the power draw 830 and/or the overvoltage protection 835, and/or accuracy the power draw 830 and/or the overvoltage protection 835), then the ML engine 820 performs further training 855 of the one or more ML models 825 by updating the one or more ML models 825 to reinforce weights and/or connections within the one or more ML models 825 that contributed to the identification of the power draw 830, encouraging the one or more ML models 825 to make similar power draw determinations given similar inputs. If the feedback 850 is negative (e.g., expresses, indicates, and/or suggests disapproval of the power draw 830 and/or the overvoltage protection 835, failure of the power draw 830 and/or the overvoltage protection 835, and/or inaccuracy of the power draw 830 and/or the overvoltage protection 835) then the ML engine 820 performs further training 855 of the one or more ML models 825 by updating the one or more ML models 825 to weaken, remove, and/or replace weights and/or connections within the one or more ML models that contributed to the identification of the power draw 830 and/or the overvoltage protection 835, discouraging the one or more ML models 825 to make similar power draw and/or overvoltage protection determinations given similar inputs.

[0107] FIG. 7 is a flow diagram illustrating a process 700 for overvoltage protection of a supercapacitor system for an electric vehicle using a controller. The controller can include a processor with access to a memory. The controller that performs the process 700 can include the system 100, the EC battery 102, the SC adder module 104, the switch and test module 106, the SC controller 116, the controller 110, the SC batteries 112, the memory 114, the base module 108, the database 118, electric vehicle 120, any system(s) that perform any of the processes of any of FIGs. 2-4, the switch 505, the components 510, the energy controller 506, the ML engine 820 of FIG. 6, an apparatus, a non-transitory computer-readable storage medium coupled to a processor, component(s) or subsystem(s) of any of these systems, or a combination thereof.

[0108] At operation 702, the controller is configured to, and can, store energy via a plurality of energy storage units that include a supercapacitors that can be arranged in a plurality of supercapacitor groups that can be exclusive and/or non-exclusive. Exclusive means that each supercapacitor belongs to a single group of supercapacitors. A non-exclusive group refers to the ability of a supercapacitor to belong to one or more groups of supercapacitors. As recited herein, each group of supercapacitors includes two or more supercapacitors.

[0109] In some examples, the controller includes a database that is configured to track the supercapacitors over time and track an overvoltage error for each of the supercapacitors. If one of the supercapacitors within a group of supercapacitors is identified as being in an overvoltage state, the group of supercapacitors can be identified as being overvoltage. If a group is identified as being overvoltage, then the group can be moved to an inactive state in the database.

[0110] At operation 704, the controller is configured to, and can, detect voltage of each of the supercapacitors. In other examples, the controller can detect change in charge and amperage of the supercapacitor. Further the controller, can record the change in charge, amperage, and/or voltage in a database.

[0111] At operation 706, the controller is configured to, and can, determine which of the plurality of supercapacitor groups to connect to the electric vehicle. In at least one example the determination can be based on a predetermined percentage of difference of at least one supercapacitor in one of the plurality of supercapacitor groups from an average value of all of the supercapacitors. In another example, the determination is based on a predetermined percentage of difference of at least one supercapacitor in one of the plurality of supercapacitor groups from an average value of available supercapacitors. Available supercapacitors refers to supercapacitors that have not previously been identified as being outside of acceptable parameters. In at least one example, the predetermined percentage is greater than 20%. In at least one example, the predetermined percentage is greater than 10%.

[0112] In at least one example, the method can include at least one overvoltage protection circuit which is electrically coupled between the plurality of supercapacitors and the electric vehicle. The at least one overvoltage protection circuit can prevent one or more of the groups of supercapacitors from being coupled to the electric vehicle. The overvoltage protection circuit prevents one or more of the groups of supercapacitors from being coupled to the vehicle when the voltage of the group of supercapacitors is outside of the predetermined percentage as recited herein. In one example, that predetermined percentage can be 10%. In another example, the predetermined percentage is greater than 20%.

[0113] In at least one example, a controller can send information to a display screen that is operable to display an error code that is generated by the controller in response to one or the supercapacitor groups in need of charging. Additionally, the display can display an error code that indicates an OVP error.

[0114] In at least one example, the controller continuously monitors the groups and determines when one or more of the groups is outside of a predetermined range; swapping out the one or more groups outside of the range with a group that is not currently connected but within the appropriate range. In at least one example, the predetermined range includes one or more of voltage, current, and/or charge capacity.

[0115] In at least one example, the controller can determine the number of groups to connect based on the total current draw that is needed in combination with the desired voltage of the same.

[0116] In at least one example, the controller can determine if the overvoltage projection unit is operational and disconnecting the group if the overvoltage protection unit is not operational.

[0117] Individual aspects may be described above as a process or method which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed, but could have additional operations not included in a figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination can correspond to a return of the function to the calling function or the main function.

[0118] Aspects of the present disclosure may be provided as a computer program product, which may include a computer-readable medium tangibly embodying thereon instructions, which may be used to program a computer (or other electronic devices) to perform a process. The computer- readable medium may include, but is not limited to, fixed (hard) drives, magnetic tape, floppy diskettes, optical disks, Compact Disc Read-Only Memories (CD-ROMs), and magneto-optical disks, semiconductor memories, such as ROMs, Random Access Memories (RAMs), Programmable Read-Only Memories (PROMs), Erasable PROMs (EPROMs), Electrically Erasable PROMs (EEPROMs), flash memory, magnetic or optical cards, or other types of media/machine-readable medium suitable for storing electronic instructions (e.g., computer programming code, such as software or firmware). Moreover, aspects of the present disclosure may also be downloaded as one or more computer program products, wherein the program may be transferred from a remote computer to a requesting computer by way of data signals embodied in a carrier wave or other propagation medium via a communication link (e.g., a modem or network connection).