US-20260129815-A1 - COOLED MODULAR POWER-CONVERTING ELECTRICAL PANEL

US20260129815A1US 20260129815 A1US20260129815 A1US 20260129815A1US-20260129815-A1

Abstract

Changing electrical power needs for buildings often requires the upgrade of the electrical panel, the addition of extra panels, or both. Herein, a single electrical panel hosts power interface modules that connect to multiple power rails within the panel. The modules, which plug into the panel, convert power between the rails, or make and break connections between the rails, under the command of a system controller. The rails are connected to switchgear to which a variety of external power sources and loads can be connected. The modules are cooled by a heat exchanger and the waste heat may be directed outside or used to heat inside the building or heat domestic water.

Inventors

Lucas Pablo Sinopoli
Carlos Javier Paredes
Mohammad Amin Zakershobeiri
Jhih-Da Hsu
Tomas Syskakis

Assignees

FUTURI POWER INC.

Dates

Publication Date: 20260507
Application Date: 20251231

Claims (20)

1 . A central controller for an electrical panel, the central controller comprising: a communications interface; connections for multiple power rails in the electrical panel; processing circuitry; and computer readable memory storing computer readable instructions, which, when executed by the processing circuitry, cause the central controller to: detect, via the communications interface, an electrical connection of each of one or more power interface modules to the central controller; and determine to which of the multiple power rails each power interface module is connectable.
2 . The central controller of claim 1 , configured to: draw power from an electrical service connected to the electrical panel; and supply DC (direct current) power to the one or more power interface modules.
3 . The central controller of claim 1 , further comprising a device interface, wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to communicate via the device interface, by wire or wirelessly, with a load that is connected to the electrical panel and/or a power source that is connected to the electrical panel.
4 . The central controller of claim 1 , configured as a module that is connectable to and removable from the electrical panel.
5 . The central controller of claim 1 , wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to determine: whether each power interface module comprises a DC-DC converter; whether each power interface module comprises an inverter; whether each power interface module comprises a rectifier; and whether each power interface module comprises interconnection circuitry that makes and breaks a direct electrical connection between at least two of the multiple power rails.
6 . The central controller of claim 1 , wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to determine whether each power interface module comprises at least one switch connected between: two connectors to make and break a direct electrical connection between two of the multiple power rails to which said two connectors are separately connected; or one connector and an external connector to make and break a direct electrical connection between one of the multiple power rails to which said one connector is connected and the external connector.
7 . The central controller of claim 1 , wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to determine all permutations of power transfer and interconnectivity available between the multiple power rails and the one or more power interface modules, as a result of each power interface module having internal circuitry connectable via or more switches to any one or more of the multiple power rails.
8 . The central controller of claim 1 , wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to command each power interface module to connect internal circuitry to or disconnect the internal circuitry from: any one or more of the power rails; or an external connector.
9 . The central controller of claim 1 , wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to: measure one or more loads to be supplied by the electrical panel; identify and measure power sources connected to the electrical panel; compute possible connection configurations of the one or more power interface modules and the multiple power rails; determine, from the possible connection configurations, a target configuration for converting and distributing power between the loads and the power sources; and control the one or more power interface modules to achieve the target configuration.
10 . The central controller of claim 1 , further comprising one or more sensor interfaces, wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to receive, via the one or more sensor interfaces, measurements of one, some or all of: a current in one or more of the multiple power rails; a voltage of one or more of the multiple power rails; a current in one or more of the one or more power interface modules; a voltage of one or more of the one or more power interface modules; a load on one or more of the one or more power interface modules; a temperature of a cooling system of the electrical panel; a pressure in the cooling system.
11 . The central controller of claim 1 , wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to: send a command to an internal controller in each power interface module; transmit data to and from external systems; change an operating mode of at least one of the one or more power interface modules; monitor a status of the electrical panel; monitor a performance of the electrical panel; monitor operation of the one or more power interface modules; communicate with a battery management system of a battery connected to the electrical panel; communicate with an electric vehicle; communicate with an electric vehicle charger; communicate with a solar array; communicate with an external power source; and/or follow an instruction received from a personal communication device.
12 . The central controller of claim 1 , configured to connect one of the one or more power interface modules to: a subset of the multiple power rails; another of the power interface modules when there are at least two thereof; a power source connected to the electrical panel; a load connected to the electrical panel; and/or an electrical service connected to the electrical panel.
13 . The central controller of claim 1 , wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to: read a unique identifier from each power interface module; determine a type of each power interface module; read a power level of at least one of the one or more power interface modules; read a history of operation of at least one of the one or more power interface modules; and read data from at least one of the one or more power interface modules via the communications interface.
14 . The central controller of claim 1 , wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to: store an inventory of the one or more power interface modules electrically connected to the electrical panel, the inventory comprising a type, a current rating, a voltage rating and a power rating for each power interface module; detect a removal of one of the one or more power interface modules from the electrical panel and/or an insertion of another power interface module in the electrical panel; update the inventory; identify power sources and loads connected to the electrical panel; reconfigure one or more connections of the one or more power interface modules in response to a change in said power sources and loads; monitor currents; monitor voltages; exchange data based on measurements to and from said power sources and loads.
15 . The central controller of claim 1 , wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to control a cooling system for the electrical panel.
16 . The central controller of claim 1 , wherein the computer readable instructions, when executed by the processing circuitry, further cause the electrical panel to direct a coolant, from a heat-exchanging zone in direct thermal contact with the one or more power interface modules, through a selectable one or more of multiple coolant outlets in the electrical panel.
17 . The central controller of claim 1 , wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to command an air diverter in the electrical panel to switch between: one setting in which air is directed through an air outlet in a side wall of the electrical panel; and another setting in which the air is directed through another air outlet, wherein the other air outlet is in the side wall, another side wall of the electrical panel or in a front cover of the electrical panel.
18 . The central controller of claim 1 , wherein the central controller is hard-wired to one or more communication lines and one or more of the multiple power rails.
19 . The central controller of claim 1 , wherein: the electrical panel has a module interface region for accepting the one or more power interface modules, each in multiple locations; and the central controller is configured to connect to the electrical panel in the module interface region.
20 . The central controller of claim 1 , further comprising an external communications interface, wherein the computer readable instructions, when executed by the processing circuitry, further cause the central controller to exchange control signals, via the external communications interface, with at least one external device, the control signals indicative of at least one of: (i) the one or more power interface modules electrically connected to the electrical panel; (ii) loads and power sources connected to the electrical panel; (iii) a configuration of the one or more power interface modules for converting and distributing power in the electrical panel; and (iv) commands transmitted to the loads and the power sources.

Description

TECHNICAL FIELD This invention relates generally to the field of power management and more specifically to a cooled, modular, power-conversion system for managing multiple power devices, sources and loads in single and multi-unit residential homes and other buildings. BACKGROUND Traditional electrical panel technology has remained unchanged for many years. Typically, after a panel is installed it cannot be upgraded unless an additional panel is connected to it or the original panel is replaced. As more and more power technologies are coming within the grasp of the average homeowner, there is an increasing need to connect solar panels, home storage batteries and electrical vehicle chargers to the panel. In line with this, the total current capacity of the panel often needs to be increased. Patent application US20220149745 to Ibrahim et al. provides a bidirectional power converter capable of receiving and delivering AC and DC power from and to multiple ports. The AC or DC input receives power and at least two power conversion circuits work with a plurality of switches. The power conversion circuits may be rectifier inverters and have a modular form, which connect to the AC and DC ports via a backplane having multiple connectors. Patent application US20120126623 to Koehl describes a modular portal system and method for harvesting energy from distributed power sources. The distributed power sources include renewable and nonrenewable energy sources, which are coupled to a backplane. The backplane receives modular preconditioner modules and inverter modules, which are inserted into module slots. The backplane also includes a controller for selectively coupling the energy harvesting system to a power grid. Patent U.S. Pat. No. 10,396,554 to Chik et al. describes controlling power distribution from a plurality of inverters to one or more loads. The method comprises determining, using one or more computer processors, a plurality of possible combinations of the plurality of inverters to meet load demands corresponding to the one or more loads. Each possible combination of the plurality of possible combinations includes a respective set of one or more inverters of the plurality of inverters. The method further comprises accessing one or more predefined efficiency functions associated with the inverters, selecting a combination, and transmitting control signals to the inverters corresponding to the selected combination to thereby power the one or more loads. Patent U.S. Pat. No. 10,277,035 to Gudgel et al. relates to a modular inverter system having a system controller module that includes several electronic switches that may be controlled to couple various nodes in the system controller module to various circuits coupled to input/output terminals at the modular inverter system to realize various modes of operation. Patent U.S. Pat. No. 6,738,692 to Schienbein et al. discloses a power conversion and energy management system with a controller, one or more standard modules, and a custom or semi-custom backplane. The backplane preferably accommodates one or more modules and uses the modules to control power quality and/or flow to one or more input and/or output connections. The standard modules are preferably power modules such as an inverter module, converter module, or grid connect module. This background is not intended, nor should be construed, to constitute prior art against the present invention. SUMMARY An electrical panel disclosed herein has multiple power rails to which multiple power interface modules connect. Each power interface module is a DC-DC converter, a rectifier, an inverter, an interconnection module or a combination of any two or more of these. The modules in the panel may be different or of the same type. A system controller in the panel or in a controller module commands the individual modules to either connect or disconnect their internal power circuitry or interconnections to or from one or more of the power rails. Depending on the embodiment, any module may be connected in any position in the panel and the system controller will identify its type, capabilities and connectability to the rails via communication with the modules on a communications bus. The system controller then commands the modules according to the requirements of the loads and sources connected to the panel. A cooling channel is present in the panel via which waste heat generated by the power interface modules is removed from the panel. The waste heat may be selectively expelled or used for beneficial purposes, such as heating a room or water. The panel may be configured so that the modules plug into sockets at both sides of the panel, and retain the modules in position. Heat is drawn from the modules, e.g. from the center or elsewhere. Disclosed herein is an electrical panel that converts electrical power and is cooled, the electrical panel comprising: a casing defining an inlet for a coolant and an outlet for the coolant; a he