WO2025073062A1

WO2025073062A1 - Low voltage power unit

Info

Publication number: WO2025073062A1
Application number: PCT/CA2024/051327
Authority: WO
Inventors: Joël Martin; Pier-luc CÔTÉ; Sina Torkestani
Original assignee: Transtech Innovations Inc
Current assignee: Transtech Innovations Inc
Priority date: 2023-10-06
Filing date: 2024-10-07
Publication date: 2025-04-10
Anticipated expiration: 2026-04-06

Abstract

Low voltage power units for vehicles are described herein. The low voltage power units may include a housing, a plurality of battery cells, an induction charger electrically coupled to the battery cells and a battery management system. The battery management system may include a processor and a communication module. The processor may instruct the communication module to transmit state of charge (SOC) and/or state of health (SOH) information to a cloud-based server upon the induction charger being charged. The units may also include a temperature control system including a cooling plate and a heating element. The cooling plate may circulate a fluid to remove heat from the battery cells. The heating element may be configured to generate heat and transmit heat to the battery cells. The units may include a load shed circuit having a plurality of load shed relays and a plurality of current limited critical load outputs.

Description

LOW VOLTAGE POWER UNIT

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of priority of co-pending U.S. Provisional Patent Application No. 63/542,969, which was filed October 6, 2023, the content of which is incorporated herein by reference in their entirety.

FIELD

[0002] This disclosure relates generally to power units, and more specifically to low voltage power units.

BACKGROUND

[0003] With the advent of electric vehicles and their release onto the market, there is enormous pressure to increase their range. Increasing their range involves, among other things, weight reduction and fuel efficiency. Due to the importance of the weight of lead- acid batteries currently used to provide auxiliary energy, the opportunity to use lithium batteries is an interesting solution considering their high energy density and their cost becoming more accessible.

[0004] In addition, the use of a battery built from lithium cells makes it possible to free up space on a vehicle without compromising its energy storage capacity. However, using lithium cells to build the auxiliary battery comes with its own set of challenges and operation over the extended temperature range of the bus environment in North America is one of them.

[0005] Accordingly, there is a need for new power units, and more specifically to new low voltage power units.

SUMMARY

[0006] In accordance with a broad aspect, a low voltage power unit for a vehicle is described herein. The low voltage power unit includes a housing; a plurality of battery cells positioned within the housing and a temperature control system. The temperature control system includes a cooling plate positioned within the housing. The cooling plate is fluidly coupled to a heat exchanger external to the housing of the power unit and a heat pump. The heat pump is configured to direct the cooling fluid to travel from the cooling plate to the heat exchanger and discharge heat from the cooling fluid at the heat exchanger. The temperature control system also includes a heating element positioned adjacent to the plurality of battery cells. The heating element is configured to generate and transmit heat to the battery cells. The unit also includes a battery management system having a processor, the processor being communicatively coupled to the heat exchanger, the heating element, the heat pump and one or more temperature sensors within the housing. The battery management system is configured to receive a first temperature of the chamber within the housing; and when the first temperature is below a threshold temperature, activate the heating element to increase the first temperature of the chamber; and when the first temperature is above the threshold temperature, activate the heat exchanger to circulate the cooling liquid through the cooling plate to reduce the first temperature of the chamber.

[0007] In accordance with a broad aspect, a low voltage power unit for a vehicle is described herein. The low voltage power unit includes a housing and a plurality of cells positioned within the housing. The low voltage power unit also includes a temperature control system. The temperature control system includes a cooling plate positioned within the housing. The cooling plate is designed to circulate a fluid from an external cooling system, the cooling plate being configured to remove heat from the cells. The temperature control system further includes a heating element positioned adjacent to the plurality of cells, the heating element being configured to generate and transmit heat to the cells. The low voltage power unit also includes a battery management system having a processor, the processor being communicatively to the heating element, the heat pump and one or more temperature sensors within the housing. The battery management system is configured to: receive a first temperature of the cells; and when the first temperature is below a threshold temperature, activate the heating element to increase the first temperature of the cells.

[0008] In accordance with a broad aspect, a low voltage power unit for a vehicle is described herein. The low voltage power unit includes a housing and a plurality of cells positioned within the housing. The low voltage power unit also includes a battery management system having a processor. The processor is communicatively coupled to a load shed circuit.. The load shed circuit includes a plurality of load shed relays and a plurality of current limited critical load outputs. Each current limited critical load output has a respective load shed relay. The battery management system is configured to receive voltage sensing data, temperature and current sensing data, and depending on the state of charge of the battery, controls the load shed relays to remove any non-essential devices from operation, prioritizing the energy to critical loads.

[0009] In accordance with a broad aspect, a low voltage power unit for a vehicle is described herein. The low voltage power unit includes a housing, and a plurality of cells positioned within the housing. The low voltage power unit also includes an induction charger electrically coupled to the batteries. The low voltage power unit also includes a battery management system having a processor and a communication module. The processor and the communication module are positioned within the housing. The processor is configured to instruct the communication module to transmit state of charge (SOC) and/or state of health (SOH) information, for example over a wireless network, to a cloud-based server when the induction charger is actively charging.

[0010] In at least one embodiment, the cooling plate is positioned beneath the cells.

[0011] In at least one embodiment, the cooling plate is fixed to the cells.

[0012] In at least one embodiment, the heating element is in contact with the cells.

[0013] In at least one embodiment, the low voltage power unit further includes one or more temperature sensors enclosed within the plastic enclosure.

[0014] In at least one embodiment, one of the critical load outputs can be coupled to a fire suppression system of a vehicle.

[0015] In at least one embodiment, one of the critical load outputs can be coupled to a surveillance system of a vehicle.

[0016] In at least one embodiment, one of the critical load outputs can be coupled to data transfer system of the vehicle. [0017] In at least one embodiment, one of the critical load outputs can be coupled to engine control system of the vehicle.

[0018] In at least one embodiment, low voltage power unit includes a main power relay, and the processor is configured to open the main power relay under a first threshold battery state of charge to remove a main load on the vehicle.

[0019] In at least one embodiment, the processor is optionally configured to open the main power relay after a predetermined period of time after power down of the vehicle.

[0020] In at least one embodiment, when the main power relay is open, the processor is further configured to open one or more of the load shed relays at a second threshold battery state of charge, optionally the second threshold battery state of charge being a lower state of charge than the first threshold battery state of charge.

[0021] In at least one embodiment, the processor is further configured to, when the battery gets down to a critical state of charge, open the main power relay and each of the load shed relays to prevent the battery from dangerous deep discharge and maintain enough power to power up the vehicle. Each startup event without battery charging at low state of charge is time-limited to prevent unnecessary power loss.

[0022] In at least one embodiment, the low voltage power unit also includes an RFID tag storing identification information of the low voltage power unit.

[0023] In at least one embodiment, the low voltage power unit also includes an RFID reader configured to passively scan an RFID tag of a vehicle when the low voltage power unit is installed in the vehicle.

[0024] In at least one embodiment, the low voltage power unit also includes a vibration sensor configured to measure vibration data of the batteries and transmit the vibration data to the battery management system.

[0025] In at least one embodiment, the low voltage power unit also includes a diagnostic connector.

[0026] In at least one embodiment, the low voltage power unit also includes a display configured to present information to a user. [0027] In at least one embodiment, the low voltage power unit also includes insulation on an inner surface of one or more sides of the housing.

[0028] In at least one embodiment, the processor is communicatively coupled to a load shed circuit. The load shed circuit includes a plurality of load shed relays and a plurality of current limited critical load outputs. Each current limited critical load output has a respective load shed relay. The battery management system is configured to receive voltage sensing data, temperature and current sensing data, and depending on the state of charge of the battery, controls the load shed relays to remove any non-essential devices from operation, prioritizing the energy to critical loads.

[0029] In at least one embodiment, the low voltage power unit also includes an induction charger electrically coupled to the batteries and the low voltage power unit also includes a battery management system having a processor and a communication module. The processor and the communication module are positioned within the housing. The processor is configured to instruct the communication module to transmit state of charge (SOC) and/or state of health (SOH) information, for example over a wireless network, to a cloud-based server when the induction charger is actively charging.

[0030] These and other features and advantages of the present application will become apparent from the following detailed description taken together with the accompanying drawings. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the application, are given by way of illustration only, since various changes and modifications within the spirit and scope of the application will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] For a better understanding of the various embodiments described herein, and to show more clearly how these various embodiments may be carried into effect, reference will be made, by way of example, to the accompanying drawings which show at least one example embodiment, and which are now described. The drawings are not intended to limit the scope of the teachings described herein. [0032] FIG. 1 is a front perspective view of a low voltage power unit, according to at least one embodiment described herein.

[0033] FIG. 2 is a front view of the low voltage power unit of FIG. 1 .

[0034] FIG. 3 is a front perspective partial cut out view of the low voltage power unit of FIG. 1.

[0035] FIG. 4 is a rear perspective view of the low voltage power unit of FIG. 1 .

[0036] FIG. 5 is a simplified electrical diagram presenting at least one embodiment of interconnections in the low voltage power unit of FIG. 1 .

[0037] Further aspects and features of the example embodiments described herein will appear from the following description taken together with the accompanying drawings.

DESCRIPTION OF EXAMPLE EMBODIMENTS

[0038] Various apparatuses, methods and compositions are described below to provide an example of at least one embodiment of the claimed subject matter. No embodiment described below limits any claimed subject matter and any claimed subject matter may cover apparatuses and methods that differ from those described below. The claimed subject matter are not limited to apparatuses, methods and compositions having all of the features of any one apparatus, method or composition described below or to features common to multiple or all of the apparatuses, methods or compositions described below. It is possible that an apparatus, method or composition described below is not an embodiment of any claimed subject matter. Any subject matter that is disclosed in an apparatus, method or composition described herein that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicant(s), inventor(s) and/or owner(s) do not intend to abandon, disclaim, or dedicate to the public any such invention by its disclosure in this document.

[0039] Furthermore, it will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the example embodiments described herein. However, it will be understood by those of ordinary skill in the art that the example embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the example embodiments described herein. Also, the description is not to be considered as limiting the scope of the example embodiments described herein.

[0040] It should be noted that terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of the modified term, such as 1 %, 2%, 5%, or 10%, for example, if this deviation does not negate the meaning of the term it modifies.

[0041] Furthermore, the recitation of any numerical ranges by endpoints herein includes all numbers and fractions subsumed within that range (e.g., 1 to 5 includes 1 , 1.5, 2, 2.75, 3, 3.90, 4, and 5). It is also to be understood that all numbers and fractions thereof are presumed to be modified by the term “about” which means a variation up to a certain amount of the number to which reference is being made, such as 1 %, 2%, 5%, or 10%, for example, if the end result is not significantly changed.

[0042] It should also be noted that, as used herein, the wording “and/or” is intended to represent an inclusive - or. That is, “X and/or Y” is intended to mean X, Y or X and Y, for example. As a further example, “X, Y, and/or Z” is intended to mean X or Y or Z or any combination thereof. Also, the expression of A, B and C means various combinations including A; B; C; A and B; A and C; B and C; or A, B and C.

[0043] The following description is not intended to limit or define any claimed or as yet unclaimed subject matter. Subject matter that may be claimed may reside in any combination or sub-combination of the elements or process steps disclosed in any part of this document including its claims and figures. Accordingly, it will be appreciated by a person skilled in the art that an apparatus, system or method disclosed in accordance with the teachings herein may embody any one or more of the features contained herein and that the features may be used in any particular combination or sub-combination that is physically feasible and realizable for its intended purpose.

[0044] The example embodiments of the devices, systems, or methods described in accordance with the teachings herein may be implemented as a combination of hardware and software. For example, the embodiments described herein may be implemented, at least in part, by using one or more computer programs, executing on one or more programmable devices comprising at least one processing element and at least one storage element (i.e. , at least one volatile memory element and at least one non-volatile memory element). The hardware may comprise input devices including at least one of a touch screen, a keyboard, a mouse, buttons, keys, sliders, and the like, as well as one or more of a display, a printer, and the like depending on the implementation of the hardware.

[0045] It should also be noted that there may be some elements that are used to implement at least part of the embodiments described herein that may be implemented via software that is written in a high-level procedural language such as object oriented programming. The program code may be written in C⁺⁺, C#, JavaScript, Python, or any other suitable programming language and may comprise modules or classes, as is known to those skilled in object-oriented programming. Alternatively, or in addition thereto, some of these elements implemented via software may be written in assembly language, machine language, or firmware as needed. In either case, the language may be a compiled or interpreted language.

[0046] At least some of these software programs may be stored on a computer readable medium such as, but not limited to, a ROM, a magnetic disk, an optical disc, a USB key, and the like that is readable by a device having a processor, an operating system, and the associated hardware and software that is necessary to implement the functionality of at least one of the embodiments described herein. The software program code, when read by the device, configures the device to operate in a new, specific, and predefined manner (e.g., as a specific-purpose computer) in order to perform at least one of the methods described herein. [0047] At least some of the programs associated with the devices, systems, and methods of the embodiments described herein may be capable of being distributed in a computer program product comprising a computer readable medium that bears computer usable instructions, such as program code, for one or more processing units. The medium may be provided in various forms, including non-transitory forms such as, but not limited to, one or more diskettes, compact disks, tapes, chips, and magnetic and electronic storage. In alternative embodiments, the medium may be transitory in nature such as, but not limited to, wire-line transmissions, satellite transmissions, internet transmissions (e.g., downloads), media, digital and analog signals, and the like. The computer useable instructions may also be in various formats, including compiled and non-compiled code.

[0048] Recently, there has been a growing interest in developing new power units, and particularly low voltage power units.

[0049] The power units described herein are generally low voltage power units to provide auxiliary power to a vehicle, particularly an electric bus or a hybrid electric bus or a diesel engine bus.

[0050] Herein, the term “low voltage” means that the power unit has an electrical potential not large enough to cause injury or damage if diverted.

[0051] In at least one embodiment, the power units described herein have a voltage output in a range of about 1V to about 100V, or in a range of about 15V to about 50V, or of about 24 V.

[0052] In at least one embodiment, the power units described herein typically include a plurality of cells, such as but not limited to lithium iron phosphate cells.

[0053] As described in greater details below, the low voltage power units described herein include a temperature control system including thermal logic, load shed logic, and/or charging logic. Any or all of these features are included in the low voltage power units. [0054] For example, as described in greater detail below, the temperature control systems described herein, which include a cooling plate, a heating and, insulation, provides for an OEM to not worry about temperature conditions of the battery.

[0055] In another example, the data acquisition functionalities described below may provide for artificial intelligence (Al) to analyze the collected data and improve predictive maintenance on the batteries, potentially preventing a number of breakdown events of the batteries during servicing.

[0056] These and other features of the low voltage power units described herein are explored in greater detail below.

TEMPERATURE CONTROL SYSTEM

[0057] Turning to the figures, FIG. 1 is a front perspective view of a low voltage power unit (LVPU) 100 according to at least one embodiment described herein. LVPU 100 includes a housing 102, an interface 104, a plurality of power posts 106, a communication/loadshedding connector 108, and cooling plate input ports 111.

[0058] Housing 102 can be any housing suitable for a low voltage power unit configured to provide auxiliary power to a vehicle, particularly an electric bus or a hybrid electric bus. For example, housing 102 may be formed of a polymeric, non-conducting material.

[0059] Interface 104 includes various communication elements to provide for a user of LVPU 100 to either control features of LVPU 100 (e.g. provide inputs to the LVPU 100) or visualize output from the LVPU 100. For example, in at least one embodiment shown in FIG. 2, interface 104 may include a display 112 configured to present information to a user. Interface 104 may also include a power button 114 configured to turn on and turn off the battery cells 109 power to the power posts 106. Interface 104 may optionally include an information button 116 for controlling what information is shown on the display 112. Information that may be shown on the display 112 may include, but is not limited to, temperature information of the batterie cells 109, voltage information, current information, and the like. As shown in FIG. 2, a service/maintenance communication connector 118 may also optionally be provided beneath interface 104.

[0060] Turning to FIG. 3, therein components of the temperature control system 110 present within housing 102 are shown. Temperature control system 110 generally provides for extended temperature operation.

[0061] Temperature control system 110 includes a cooling plate 115 positioned within the housing 102. In the embodiment shown in FIG. 3, cooling plate 115 is positioned beneath the plurality of battery cells 109. In at least one embodiment, the cooling plate 115 is an aluminum block positioned within housing 102 and the cells 109 are fixed to a top surface of the aluminum block, for example by a thermally conductive adhesive 116. In at least one embodiment, the cells 109 may be retained within housing 102 by a holding bracket 117. Holding bracket 117 may also be fixed to a top surface of the cooling plate 115.

[0062] Cooling plate 115 is fluidly coupled to a heat exchanger (not shown). In at least one embodiment, the heat exchanger is external to the housing 102 of the LVPU 100 and is configured to receive a cooling fluid (e.g., water, a refrigerant, or another appropriate cooling fluid) from the cooling plate 115 and extract the collected heat from the cooling fluid. Temperature control system 110 may also include a heat pump (e.g. a compressor) configured to move the cooling fluid through the refrigeration cycle. The heat pump may optionally be positioned within the housing 102 or may optionally be positioned exterior to housing 102. In at least one embodiment, the temperature control system 110 does not include any fans or any forced air.

[0063] Temperature control system 110 also includes a heating element 120 positioned adjacent to the plurality of battery cells 109. FIG. 4 is a rear perspective view of the low voltage power unit of FIG. 1 showing one exemplary position of the heating element 120 relative to battery cells 109.

[0064] Heating element 120 is configured to generate and transmit heat to the battery cells 109, particularly when the temperature of the battery cells 109 falls below a threshold temperature. Heating element 120 may be an electric heating pad or the like and heat can be transferred from the heating pad to the batterie either by conduction (i.e. the heating pad is in direct contact with the batteries 109) or by convection (i.e. the heating pad is not in direct contact with the batteries 109). It should be understood that the heating pad may also transfer heat to the batteries 109 using a combination of these heat transfer techniques.

[0065] Temperature control system 110 also includes a battery management system (BMS) 122. BMS 122 is shown in FIG. 4 as being positioned on top of battery cells 109, however, it should be understood that BMS 122 may be positioned in other places within the housing 102.

[0066] BMS 122 includes a processor 124 communicatively coupled to the heating element 120, the cooling plate 115, and one or more temperature sensors positioned within the housing. Processor 124 of BMS 122 is configured to receive temperature data including a temperature of the interior of the housing 102 and of the battery cells 109 from one or more temperature sensors (not shown). When the temperature is below a threshold temperature, processor 124 of BMS 122 is configured to activate the heating element to heat the battery cells 109 and increase the temperature of the battery cells 109 and/or the battery enclosure. Cooling liquid circulating through the cooling plate 115 helps to regulate the temperature of the cells 109 and/or the battery enclosure by allowing an optimum temperature liquid to flow through the cooling plate input ports 111 .

[0067] In at least one embodiment, by inverting the heat pump, in the option where the heat pump is provided, it is also possible to use the heat pump to heat the battery cells 109. One advantage of having a heat pump is its higher than 100% efficiency in heating mode, lowering the energy required to maintain the battery cells 109 above a threshold temperature. In the case shown in the drawings, liquid is provided by an external liquid temperature management system. The liquid is maintained at a predefined range of temperature, set to as optimum for a good battery operating temperature.

[0068] BMS 122 may optionally include a logging storage unit configured to store temperature data collected from the one or more temperature sensors noted above. [0069] In at least one embodiment, the temperature control system 110 is configured to autonomously keep an internal temperature of the battery enclosure within a range of about 15°C and about 25°C, for example. However, it should be understood that, depending on state of charge conditions and power mode of the LVPU 100, the temperature setpoint may change dynamically.

[0070] In at least one embodiment, as shown in FIG. 3, LVPU 100 may optionally include insulation 125 on one or more inner surfaces of housing 102.

[0071] In at least one embodiment, a temperature sensor may be included to the enclosure of housing 102 to provide BMS 122 within temperature information about external temperature changes in order to provide information for feed-forward regulation, optionally.

LOAD SHEDDING

[0072] LVPU 100 may also be configured to provide for load shedding at multiple and/or low states of charge. To provide for load shedding, LVPU 100 includes a communication/loadshedding connector 108, as shown and detailed in FIG. 1. The multiple levels of load shedding provide for LVPU 100 to power critical loads independently from other loads on the vehicle. Critical loads can be connected separately from the other loads through a critical load current limited output. Further, load shedding as described herein may ensure that LVPU 100 has enough power to start the vehicle, even after the vehicle having been inactive for extended periods of time.

[0073] Turning to FIG. 5, shown therein is a simplified electrical diagram presenting at least one embodiment of interconnections in the LVPU 100 when it is configured to provide for load shedding at multiple and/or low states of charge. The electrical diagram of FIG. 5 shows that battery cells 109 are electrically coupled to the BMS 122, which is configured for providing voltage sensing and temperature sensing functions (e.g. by receiving data from voltage sensors and temperature sensors, respectively). Battery cells 109 are also electrically coupled to a load shed circuit 130 and an optional precharge circuit 132. [0074] Load shed circuit 130 includes multiple load shed relays 134 and multiple current limited critical load outputs 136. Each current limited critical load output 136 has a respective load shed relay 134. BMS 122 is communicatively coupled to each load shed relay 134, precharge circuit, and power relay 138 and includes load shedding logic adapted for critical application of bus. More specifically, the main power relay may be opened under a certain threshold battery state of charge to remove the main loads on the bus. This can be done also using a timer after power down of the vehicle. After this first level of load shedding, the other critical load shedding output relays 134 are opened at different state of charge down to the critical value of state of charge. When the battery gets down to a critical state of charge, all the relays are opened to prevent the battery from dangerous deep discharge and keep just enough power for a bus power up.

[0075] As one example, the Battery Management System (BMS) 122 can selectively or intelligently deactivate electrical loads as needed. The BMS 122 operates as a software-driven autonomous power control device that automatically manages power distribution to various critical loads. This includes functionalities such as automatic load shutoff, or load shedding, to optimize energy usage. The system is designed to control the load shed relays based on the state of charge of the battery cells, allowing it to disconnect non-essential devices and prioritize energy for critical loads.

[0076] It should be understood that there is no load shedding while the vehicle is in function.

[0077] The critical loads may include but may not be limited to a camera on the vehicle, a fire suppression system, data transfer and engine control systems.

INDUCTION CHARGING AND WIRELESS COMMUNICATION

[0078] The low voltage power units described herein may also optionally be configured for autonomous, induction charging and/or to communicate wirelessly with an external cloud server, for example for the cloud server to collect data stored on the low voltage power unit. [0079] Returning to FIG. 5, as shown in the diagram therein, LVPI1 100 may optionally include an induction charger 140. Induction charger 140 may provide for wirelessly charging the LVPU 100, for example when it is not installed in a vehicle. In at least one embodiment described herein, LVPU 100 may be a component of a charging system including a smart shelf (not shown herein). The smart shelf may be configured for autonomously charging the LVPU 100 upon placement of the LVPU 100 on an induction charging unit of the smart shelf.

[0080] In at least one embodiment, LVPU 100 may also optionally include a Wi-Fi communication module 142. Wi-Fi communication module 142 provides for the processor of the BMS 122 to transmit and receive data with a cloud based server, for example. In these embodiments, BMS 122 may transmit temperature data stored in logging storage of the BMS 122 to a cloud based server. In one embodiment, the processor of BMS 122 may store instructions indicating when the temperature data is to be pushed to the cloud, for example when the Wi-Fi communication module 142 establishes a connection with a known Wi-Fi network (e.g. when the vehicle enters a bus garage, or returns home, or the like). In another embodiment, the cloud server may be programmed to transmit a signal to the LVPU 100 to retrieve the temperature data from the LVPU 100, for example when the Wi-Fi communication module 142 establishes a connection with a known Wi-Fi network (e.g. when the vehicle enters a bus garage, or returns home, or the like).

[0081] In at least one embodiment, LVPU 100 may optionally include an RFID tag (not shown) and/or an RFID reader 144. In at least one embodiment, the RFID tag may include identification information of the LVPU 100. When the RFID tag is scanned, for example by a user when the LVPU 100 is installed in a vehicle, identification information of the LVPU 100 may be transmitted to the scanner. In some embodiments, the RFID tag may be actively scanned by a user or may be passively scanned autonomously when the LVPU 100 is installed in the vehicle and the vehicle enters a defined geographical area, such as but not limited to a bus garage. This may provide for the location of the LVPU 100 to be known to the cloud based server as soon as the LVPU 100 enters the garage. In other embodiments, passively scanning the RFID tag as the bus enters a garage may trigger transfer of other information from the LVPU 100 to the cloud based server, such as but not limited to the transfer of voltage information and/or temperature information and/or state of charge of the LVPII 100.

[0082] In at least one embodiment, the LVPU 100 may be passively scanned when the LVPU 100 is placed on a smart shelf. In this embodiment, a precise position of the LVPU 100 may be known and provided to the cloud based server when the LVPU 100 is being charged on the smart shelf. For example, passively scanning the RFID tag as the LVPU 100 is positioned on a smart shelf may trigger transfer of other information from the LVPU 100 to the cloud based server, such as but not limited to the transfer of voltage information and/or temperature information of the LVPU 100.

[0083] In another embodiment, the LVPU 100 may include an RFID reader 144. In one example, RFID reader 144 may passively scan an RFID 100 in a vehicle when the LVPU 100 is installed in a vehicle. In this example, LVPU 100 may receive identification information of the vehicle and, optionally, be configured to transmit the identification information of the vehicle to the cloud based server, for example when the vehicle establishes a connection with a known Wi-Fi network.

[0084] In at least one embodiment, LVPU 100 may include a vibration sensor. Vibration sensor may collect vibration data related to the LVPU 100. It has been shown that vibrations may negatively impact performance of a LVPU such as LVPU 100. By collecting vibration date and transmitting the vibration data from the LVPU to the cloud, artificial intelligence may be used to analyze the vibration data and proactively predict future mechanical failures before they occur.

[0085] In at least one embodiment, LVPU 100 is J1939 communication ready to command DCDC converter (others usually communicate battery parameters over CAN, maximum current, but not include direct DCDC converter command logic).

[0086] In at least on embodiment, LVPU 100 is configured to control the field current of an alternator to regulate the alternator output voltage and, this way, control the charging current of the battery on the bus. This option is enabled for example for diesel engine buses. [0087] In at least one embodiment, LVPII 100 is enabled for CAN bus J1939 communication.

[0088] In at least one embodiment, LVPU 100 may be connected to a vehicle monitoring diagnostic system and receive information from the vehicle monitoring diagnostic system.

[0089] In at least one embodiment, the cloud-based server may be configured to store any data received from the LVPU 100 and process the data received from the LVPU 100, for example using Al analysis, to more accurately predict failures of the LVPU 100.

[0090] In at least one embodiment, the LVPU 100 includes an ignition low feature that enables the battery to be “woken up” by applying a ground potential to a designated pin, allowing the battery to wake up without the need for additional energy.

[0091] Optionally, the LVPU 100 incorporates a power supply positioned between the battery cells 109 and the posts 106 of the LVPU (see, for example FIG. 3). This power supply is designed to facilitate the charging of the battery using any input voltage within the specified range of auxiliary voltage. This feature allows for versatile charging options, ensuring efficient battery replenishment regardless of the input voltage level. This power supply can optionally manage the entire charging process or focus solely on the final phase, where maintaining constant voltage is critical. This capability may enhance energy efficiency on the bus by reducing the auxiliary voltage, thereby lowering the power consumption of all connected devices.

[0092] In at least one embodiment, the LVPU enclosure features L-shaped bus bars at the front, enabling the top-mounted power posts to accommodate various installation configurations in the field.

[0093] Cold plate input connectors may optionally be compatible with quick-connect types for easy removal of the cooling harnesses from the LVPU.

[0094] While the applicant's teachings described herein are in conjunction with various embodiments for illustrative purposes, it is not intended that the applicant's teachings be limited to such embodiments as the embodiments described herein are intended to be examples. On the contrary, the applicant's teachings described and illustrated herein encompass various alternatives, modifications, and equivalents, without departing from the embodiments described herein, the general scope of which is defined in the appended claims.

Claims

CLAIMS What is claimed is:

1 . A low voltage power unit for a vehicle, the low voltage power unit comprising: a housing; a plurality of battery cells positioned within the housing; a temperature control system comprising: a cooling plate positioned within the housing, the cooling plate fluidly coupled to a heat exchanger external to the housing of the power unit and a heat pump, the heat pump configured to direct the cooling fluid to travel from the cooling plate to the heat exchanger and discharge heat from the cooling fluid at the heat exchanger; and a heating element positioned adjacent to the plurality of battery cells, the heating element being configured to generate and transmit heat to the battery cells; and a battery management system having a processor, the processor being communicatively coupled to the heat exchanger, the heating element, the heat pump and one or more temperature sensors within the housing, the battery management system being configured to: receive a first temperature of the chamber within the housing; and when the first temperature is below a threshold temperature, activate the heating element to increase the first temperature of the chamber; and when the first temperature is above the threshold temperature, activate the heat exchanger to circulate the cooling liquid through the cooling plate to reduce the first temperature of the chamber.

2. A low voltage power unit for a vehicle, the low voltage power unit comprising: a housing; a plurality of battery cells positioned within the housing; a temperature control system comprising: a cooling plate positioned within the housing, the cooling plate being configured to circulate a fluid from an external cooling system to remove heat from the cells; and a heating element positioned adjacent to the plurality of battery cells, the heating element being configured to generate and transmit heat to the battery cells; and a battery management system having a processor, the processor being connected to one or more temperature sensors within the housing, the battery management system being configured to: receive a first temperature of the battery cells; and when the first temperature is below a threshold temperature, activate the heating element to increase the first temperature of the battery cells.

3. A low voltage power unit for a vehicle, the low voltage power unit comprising: a housing; a plurality of battery cells positioned within the housing; and a battery management system having a processor, the processor being positioned within the housing and communicatively coupled to: a load shed circuit including a plurality of load shed relays and a plurality of current limited critical load outputs, each current limited critical load output having a respective load shed relay, the battery management system being configured to receive voltage sensing data, temperature and current sensing data and, depending on a state of charge of the batter cells, control the load shed relays to remove any non-essential devices from operation, prioritizing the energy to critical loads.

4. A low voltage power unit for a vehicle, the low voltage power unit comprising: a housing; a plurality of battery cells positioned within the housing; an induction charger electrically coupled to the battery cells; and a battery management system having a processor and a communication module, the processor and the communication module being positioned within the housing, the processor being configured to instruct the communication module to transmit state of charge (SOC) and/or state of health (SOH) information to a cloudbased server upon the induction charger being charged.

5. The low voltage power unit of any one of claims 1 to 4, wherein the cooling plate is positioned beneath the battery cells.

6. The low voltage power unit of claim 5, wherein the cooling plate is fixed to the battery cells.

7. The low voltage power unit of claim 1 , wherein the heat pump is positioned within the housing.

8. The low voltage power unit of claim 1 or claim 2, wherein the heating element is in contact with the battery cells.

9. The low voltage power unit of claim 1 further comprising one or more temperature sensors enclosed within the plastic enclosure to measure an external temperature.

10. The low voltage power unit of claim 3, wherein at least one of the critical load outputs is coupled to a fire suppression system of a vehicle.

11 . The low voltage power unit of claim 3, wherein one of the critical load outputs is coupled to a surveillance system of a vehicle.

12. The low voltage power unit of claim 3, wherein one of the critical load outputs is coupled to data transfer system of the vehicle.

13. The low voltage power unit of claim 3, wherein one of the critical load outputs is coupled to engine control system of the vehicle.

14. The low voltage power unit of claim 3, wherein the low voltage power unit includes a main power relay and the processor is configured to open the main power relay under a first threshold battery state of charge to remove a main load on the vehicle.

15. The low voltage power unit of claim 14, wherein the processor is configured to open the main power relay after a predetermined period of time after power down of the vehicle.

16. The low voltage power unit of claim 14 or claim 15, wherein, when the main power relay is open, the processor is further configured to open one or more of the load shed relays at a second threshold battery state of charge, optionally the second threshold battery state of charge being a lower state of charge than the first threshold battery state of charge.

17. The low voltage power unit of claim 16, wherein the processor is further configured to, when the battery gets down to a critical state of charge, open the main power relay and each of the load shed relays to prevent the battery from dangerous deep discharge and maintain enough power to power up the vehicle.

18. The low voltage power unit of claim 4 further comprising an RFID tag storing identification information of the low voltage power unit.

19. The low voltage power unit of claim 4 further comprising an RFID reader configured to passively scan an RFID tag of a vehicle when the low voltage power unit is installed in the vehicle.

20. The low voltage power unit of claim 4 further comprising a vibration sensor configured to measure vibration data of the battery cells and transmit the vibration data to the battery management system.

21. The low voltage power unit of any one of claims 1 to 20 further comprising a configuration maintenance connector.

22. The low voltage power unit of any one of claims 1 to 21 further comprising a display configured to present information to a user.

23. The low voltage power unit of any one of claims 1 to 22 further comprising insulation on an inner surface of one or more sides of the housing.

24. The low voltage power unit of claim 1 or claim 4, wherein the processor is further communicatively coupled to: a load shed including a plurality of load shed relays and a plurality of current limited critical load outputs, each current limited critical load output having a respective load shed relay, the battery management system being configured to receive voltage sensing data and, in response to the voltage sensing data, control the load shed relays to prevent simultaneous operation of an output of the power unit and the critical load outputs.

25. The low voltage power unit of claim 1 , wherein the processor is further communicatively coupled to: a load shed circuit including a plurality of load shed relays and a plurality of current limited critical load outputs, each current limited critical load output having a respective load shed relay, the battery management system being configured to receive voltage sensing data and, in response to the voltage sensing data, control the load shed relays to prevent simultaneous operation of an output of the power unit and the critical load outputs; and the low voltage power unit further comprises an induction charger electrically coupled to the battery cells, the processor being configured to instruct the communication module to transmit state of charge (SOC) and/or state of health (SOH) information to a cloud-based server when the induction charger is actively charging.

26. The low voltage power unit of claim 1 further comprising a designated pin to receive a ground potential to wake up the low voltage power unit.

27. The low voltage power unit of claim 1 further comprising a power supply positioned between the battery cells and posts of the low voltage power unit.

28. The low voltage power unit of claim 27, wherein the power supply is designed to facilitate charging of the battery cells using any input voltage within a specified range of auxiliary voltage.

29. The low voltage power unit of claim 1 , wherein one or more L-shaped bus bars are positioned within the housing to provide for top-mounted power posts to accommodate various installation configurations.