Description:Field of the invention
[0001] The present invention relates to a hybrid energy management system. More specifically, the present invention pertains to a hybrid energy management system for harvesting, storing, and distributing energy on demand basis.
Background of the invention
[0002] The increasing global demand for efficient and sustainable energy solutions has driven the development of advanced energy management systems. Traditional energy systems have primarily relied on single-source fuels, which often lack the flexibility to adapt to varying fuel supplies and environmental conditions. The inability to seamlessly integrate multiple fuel types and energy sources into a unified system has posed significant challenges. For example, solar and wind energy generate DC power but both are weather dependent sources, while grid electricity is typically AC, which is often unavailable in remote areas. Many systems struggled with converting these energy forms seamlessly, leading to energy losses and reduced overall efficiency. The lack of sophisticated conversion mechanisms meant that energy from different sources could not be utilized optimally. In addition, integrating renewable energy sources into conventional energy systems presented significant technical challenges. Solar and wind energy are inherently variable, leading to instability in power supply. Prior systems lacked the advanced management and storage capabilities required to balance these fluctuations, resulting in unreliable power delivery and frequent disruptions.
[0003] Traditional systems often suffer from poor thermal regulation, leading to overheating, reduced efficiency, performance drops in high altitudes, high temperatures, frequent breakdowns, and shortened lifespan of critical components. Inadequate insulation and cooling mechanisms further exacerbated these issues. Additionally, the design of traditional energy systems often made maintenance and upgrades cumbersome and costly.

[0004] Furthermore, safety protocols in traditional systems were often insufficient to address the risks associated with handling multiple fuel types and high-power operations. Overcharging, deep discharging, and overheating posed significant risks, particularly in systems without robust battery management systems (BMS) and real-time monitoring capabilities.
[0005] Military operations, particularly those conducted by forces like the defence, often occur in remote, inaccessible, and harsh climatic conditions. These environments, ranging from extreme heat and cold to tropical and coastal regions, present significant challenges for energy management and supply. The critical need for reliable power to support modern mission-critical technologies, such as weapon systems, sensors, radars, surveillance, and communication devices, is paramount. However, these locations frequently suffer from unreliable electricity grids with frequent and prolonged outages, further complicating the situation.
[0006] Traditional solutions, such as fossil fuel-powered generator sets, come with several drawbacks. They are bulky, overweighted, generate thermal radiation and noise, require regular maintenance, and are prone to frequent breakdowns, especially in extreme weather conditions. Additionally, these generators face starting issues in cold conditions, particularly in high-altitude areas. The high fluctuations in power output from these generators can damage costly mission-critical technologies, leading to performance drops and affecting operations.
[0007] The logistical challenges associated with transporting fossil fuels to remote or combat areas add another layer of complexity and risk. These supply chains are not only expensive but also consume substantial energy, thereby increasing the overall operational costs and reducing efficiency. The reliance on fossil fuels also creates a significant environmental impact, which is increasingly becoming a concern for military operations worldwide. The need for energy solutions that are compact, lightweight, and man-portable is becoming more urgent.

[0008] In combat and remote areas, maintaining stealth and reducing human involvement in logistics is critical. Traditional generators, with their noise and thermal signatures, compromise the camouflage and safety of troops. Additionally, the high dependency on human resources for maintaining constant readiness due to the logistical demands and operation of traditional energy solutions is a significant drawback. The operational efficiency of forces is impacted by the substantial human component involved in logistics and operation, which ideally should be minimized. Moreover, the incorporation of unmanned, intelligent energy management on demand basis with remote management and monitoring features is essential to ensure seamless operation and maintenance, further enhancing the efficiency and reliability of the energy supply in extreme conditions and can readily connect with a plurality of energy supply simultaneously.
[0009] Therefore, there is a need for a hybrid energy management system on demand basis which overcomes all drawbacks of the above-mentioned prior art.

Objects of the invention
[0010] An object of the present invention is to provide a hybrid energy management system for harvesting, storing, and distributing energy on a demand basis, which is reliable and lightweight, that can be installed anywhere at any times, in all weather conditions and terrains for mission critical applications.
[0011] Another object of the present invention is to provide a hybrid energy management system capable of making decisions, through advanced control algorithms, optimizing energy use based on real-time data and demand.
[0012] Another object of the present invention is to provide a hybrid energy management system in which is hybrid in nature that can integrate multiple energy sources or storage technologies, for enhancing efficiency and reliability.
[0013] Another object of the present invention is to provide a hybrid energy management system capable of dynamic on-demand energy management, offering superior adaptability and flexibility compared to traditional systems.
[0014] Another object of the present invention is to provide a hybrid energy management system capable of more in energy harvesting potentially utilizing renewable sources like solar or wind or solid oxide fuel cells and non-renewable sources like grid or DG sets.
[0015] Another object of the present invention is to provide a hybrid energy management system capable of more in storage and distribution, where the invention emphasizes the system's role not only in generating and storing energy but also in efficiently distributing it where and when needed. and can readily connect with a plurality of energy supply simultaneously.
[0016] Another object of the present invention is to provide a hybrid energy management system capable of operating with multiple fuel types and multiple battery chemistries, ensuring compatibility with various energy sources, including renewable and non-renewable sources, as well as current and legacy systems.
[0017] Another object of the present invention is to provide a hybrid energy management system with a universal charger with an innovative tracking algorithm that maximizes energy harvest by locking to the optimum MPPT (Maximum Power Point tracking).
[0018] Another object of the present invention is to provide a hybrid energy management system with a flexible charge algorithm that allows the selection of pre-set charge algorithms, or alternatively fully programmable charge algorithms.
[0019] Another object of the present invention is to provide a hybrid energy management system with individual control of all input sources and outputs supply and enable switches to energise the complete system to avoid energy losses and unnecessary incidents.
[0020] Yet another object of the present invention is to provide a hybrid energy management system that can withstand extreme environmental conditions, and harsh conditions, including temperature extremes, high altitude areas, high humidity, dust, and physical impacts.
[0021] One more object of the present invention is to provide a hybrid energy management system that can operate and store within a wide temperature range.
[0022] It is further object of the present invention is to provide a hybrid energy management system that is user friendly, lightweight, compact in size and portable for easy transport anywhere.
[0023] A further object of the present invention is to provide a hybrid energy management system that is multi-utility, silent in operation, and highly reliable for mission critical applications.
[0024] Furthermore, the object of the present invention is to provide a hybrid energy management system that can be managed and monitored on the table as well as remotely as per the requirement.
[0025] Furthermore, an object of the present invention is to operate an energy network, which includes the step of connecting a plurality of substantially identical hybrid energy management systems together on a single platform using an available wired or wireless or optical fibre or satellite network.

Summary of the invention
[0026] According to the present invention, a hybrid energy management system for harvesting, storing, and distributing energy on demand basis is provided. The hybrid energy management system includes a ruggedized enclosure, a power source, a battery system a charging unit, a multiple output configuration unit, and an in-built decision-making unit. The ruggedized enclosure houses the system. The enclosure is made of cold-rolled close annealed (CRCA) material.
[0027] The power source is configured to operate with multiple fuel types. The battery system is compatible with multiple battery chemistries and is electrically connected to the power source. The charging unit is capable of charging the battery system using multiple energy sources including renewable and non-renewable energy sources.
[0028] The multiutility system intelligently manages multiple input sources, stores energy, and provides electrical power in both Alternate Current (AC) and Direct Current (DC) forms through a versatile output configuration unit. The AC output is configured to deliver a 230 V pure sinewave and the DC output is configured to deliver voltages of 5, 12, 24, and 48V.
[0029] In an aspect of the invention, the decision-making unit is configured to monitor the load requirements and battery state of charge (SoC) of the system to switch the power source based on a predefined algorithm. The decision-making unit includes a virtual switch embedded in software for switching the power source ON and OFF based on at least one user-defined condition including battery state of charge and/or availability of renewable energy sources.
[0030] In an aspect of the invention, the predefined algorithms for the decision-making unit include the following steps. The current load requirements of the system are monitored and compared against a predefined load threshold with inbuilt protection.
[0031] The predefined load thresholds are the electrical load levels at which the system automatically activates the additional power sources to meet the demand or deactivate the power sources for conserving energy. The battery state of charge (SoC) of the system is assessed to determine if the charge falls below a critical level. The power source activation is prioritized based on the availability of renewable sources before non-renewable sources.
[0032] The power source is then adjusted to maintain an optimal battery state of charge (SoC) to ensure continuous power supply. After that a priority protocol is implemented to switch the power sources ON in response to the load increases or low battery state of charge SoC, while delaying power source deactivation to prevent power interruptions.
[0033] The components including the power source, battery system, charging unit, multiple output configuration unit, decision-making unit, and virtual switch in the system are then initialized and started by identifying the connected battery type and by loading the appropriate battery management profile. The voltage, current, and temperature of the system is then monitored continuously with inbuilt protection. Regular checking of the battery state of charge (SoC) of the system is done and the charging process and balancing of the cells within each battery type is managed along with battery charge/discharge cycles to prolong lifespan. Finally, the power is supplied to the load as needed based on the battery state of charge (SoC) of the system.
[0034] In an aspect of the invention, the user-defined conditions for switching the power source ON and OFF includes the following steps. The battery state of charge (SoC) is detected if the battery level is falling below a predetermined threshold. An increase in load demand above a predefined level is then identified.
[0035] The use of renewable energy sources when available is prioritized and a reserve power level for critical operations is maintained. The over-discharge of batteries is then prevented by switching to an alternative power source. The backup power sources are activated when primary power sources fail.
[0036] The power source activation based on time-of-day or operational requirements is scheduled and the power source transitions is manged to avoid disruptions during sensitive operations. The battery power is switched if the load is less than 20% of the solid oxide fuel cell capacity to avoid inefficiencies and the fuel cell and battery power is combined if the load exceeds 80% of the fuel cell capacity. After that the battery usage of the system is prioritized if the battery state of charge is high which is greater than 80% and charging the battery using solid oxide fuel cell power is prioritized if the battery state of charge is low which is less than 20%.
[0037] In an aspect of the invention, the priority protocol includes the following steps. Initially the additional power sources are switched ON when the load demand exceeds a predefined threshold. The backup power sources are then activated when the battery state of charge (SoC) falls below a critical level to prevent power outages. The active power sources are maintained for a minimum period after load demand decreases to avoid frequent switching and power interruptions and the power sources are deactivated based on decreasing load demand and battery state of charge (SoC) is recovered to ensure continuity of power supply. The load requirements and the battery state of charge are then continuously monitored. The battery power is switched if the load is less than 20% of the fuel cell capacity to avoid inefficiencies and the fuel cell and battery power is combined if the load exceeds 80% of the fuel cell capacity. After that the battery usage of the system is prioritized if the battery state of charge is high which is greater than 80% and charging the battery using fuel cell power is prioritized if the battery state of charge is low which is less than 20%.
[0038] In an aspect of the invention, intelligently manage or pre-defined algorithms with or without human intervention the renewable energy sources include solar energy, wind energy, solid oxide fuel cell (SOFC) and the non-renewable energy sources include grid/ DG Sets energy.
[0039] In an aspect of the invention, the system includes a plug-and-play architecture, which despite military standard multiple input and output ports has sufficiently been idiot proofed for connecting the system (100) to any DC source, such as solar PV, solid oxide fuel cells (SOFC), standalone batteries, and wind power and enabling connection to any AC source such as grid and generator sets.
[0040] In an aspect of the invention, the system operates within an extreme temperature range of -40°C to +55°C, with storage capabilities from -60°C to +71°C.
[0041] In an aspect of the invention, the overall capacity of the system is around 2500 Wh and the system includes a Rectiverter (90) with a capacity of 500 W to 2000W to convert DC power to AC power and vice versa, for using both AC and DC energy sources for charging the battery system and the scalability is there can be customised as per requirements.
[0042] In an aspect of the invention, the system includes a universal charger capable of identifying the battery type and rating, switching to standby mode when fully charged, and adjusting output voltage and current as required with inbuilt protection.
[0043] In an aspect of the invention, the system is capable of operating at altitudes up to 19,000 feet or more and can be customised as per requirement.
[0044] In an aspect of the invention, the battery management system includes sensors for monitoring health, requirement, voltage, current, temperature, and state of charge (SoC) for each battery type with inbuilt protection.
[0045] In an aspect of the invention, the system includes a fuel management system capable of identifying the type of fuel being supplied and balances fuel usage, reducing operation costs and environmental impact and supporting operation without requiring any additional hardware changes.
[0046] In an aspect of the invention, the system includes a control unit configured to manage power distribution based on predetermined priorities for connected devices, including surveillance equipment, sensors, and communication devices wherein the control unit includes machine learning algorithms for predicting operational parameters based on previous data and current inputs in the system.
[0047] In an aspect of the invention, the system includes an automatic generator start/stop control system programmable to auto-start/stop the system based on low-voltage, high-demand, or battery state of charge.
[0048] In an aspect of the invention, the system includes military-grade connectors with extensions to facilitate quick deployment and connection to a military equipment.
Brief Description of drawings
[0049] The advantages and features of the present invention will be understood better with reference to the following detailed description and claims taken in conjunction with the accompanying drawings, wherein like elements are identified with like symbols, and in which:
[0050] Figure 1 illustrates the block diagram of a hybrid energy management system in accordance with the present invention;
[0051] Figure 2 illustrates the working diagram of the hybrid energy management system in accordance with the present invention;
[0052] Figure 3 illustrates the schematic representation of the hybrid energy management system in accordance with the present invention;
[0053] Figure 4 illustrates a method describing the predefined algorithms for the decision-making unit in accordance with the present invention;
[0054] Figure 5 illustrates a method describing the user-defined conditions for switching the power source ON and OFF in accordance with the present invention;
[0055] Figure 6 illustrates a method describing the priority protocol in accordance with the present invention;
[0056] Figure 7 and Figure 8 illustrates cross sectional view of solid oxide fuel cell from inner to outer layer;
[0057] Figure 9 illustrates the schematic representation of the oxygen reaction at cathode material of the solid oxide fuel cell;
[0058] Figure 10 and Figure 11 illustrates anode material and the schematic diagram of the metallic electrocatalyst on anode composite substrate of the solid oxide fuel cell; and
[0059] Figure 12 illustrates the test results demonstrating the system’s resilience to environmental factors such as temperature extremes, moisture, dust, physical impacts, operation in high altitudes as per military standards.

Detailed description of the invention

[0060] An embodiment of this invention, illustrating its features, will now be described in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items or meant to be limited to only the listed item or items.
[0061] The present invention relates to a hybrid energy management system for harvesting, storing, and distributing energy on demand basis. The system operates within a temperature range of -40°C to +55°C, with storage capabilities from -60°C to +71°C and is capable of operating at altitudes up to 19,000 ft or more. The system includes military-grade connectors with extensions to facilitate quick deployment and connection to a military equipment.
[0062] The terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
[0063] The disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms.
[0064] Referring now to figures 1, a hybrid energy management system in accordance with the present invention is provided. The hybrid energy management system is to provide an efficient, adaptable, and reliable power supply that integrates multiple energy sources, both renewable (solar, wind, Solid Oxide Fuel Cell) and non-renewable (Grid/ DG Sets). The hybrid energy management system provides a resilient solution for managing diverse energy sources and on demands basis, suitable for a wide range of applications, including residential, commercial, industrial, and military uses. The hybrid energy management system is herein after referred as the “system (100)”. The system (100) includes an enclosure (20), a power source (30), a battery system (40), a charging unit (50), a multiple output configuration unit (60), and a decision-making unit (70).
[0065] The enclosure (20) is a ruggedized enclosure that houses the entire system (100). The enclosure (20) is made of cold-rolled close annealed steel (CRCA) material with a heat reflective coating to withstand extreme environmental conditions. Specifically, the enclosure (20) is made of a modular CRCA steel panel, allowing for easy assembly and disassembly with dimple technology to get more beautiful look, strength in sheet, provide heat sink features, and covers thermosetting powder coatings with Chemical Agent Resistant Coating (CARC) technology, characteristics for ease of decontamination upon exposure to chemical warfare agents (CWA). It also provides superior camouflage properties for possession of a defined infrared (IR) signature, derived from specific pigments, thus reducing visibility of coated equipment to enemy forces with a heat reflective coating to withstand extreme environmental conditions and camouflage olive-green/black matte finish powder coating is resistant to corrosion, heat and abrasion. This includes evolution of powder coating offers a solvent-free finishing technique and addresses the following requirements such as survivability of the war fighter, durability corrosion resistance, green initiatives that focus on lowering Volatile Organic Compound (VOCs) and Hazardous Air Pollutants (HAPs), plus the ability to reuse overspray.
[0066] In the preferred embodiment, the specification of the steel used in the enclosure (20) ranges from 1.5mm to 1.8mm in thickness with a yield strength of around 210-370 MPa and a tensile strength of approximately 270-410 MPa. The enclosure (20) can withstand mechanical stresses and impacts in harsh environments. The heat reflective coating reduces the thermal load on the enclosure (20) by reflecting a high percentage of solar and radiant heat. The heat reflecting coating has a reflectivity = 80% and a thermal emissivity = 0.25 for minimizing the heat absorption, and for maintaining a lower internal temperature in extreme sunlight. The heat reflective coating is durable, resistant to UV radiation, with a weathering suitable for long-term protection of the enclosure (20). The heat reflective coating is applied in a thickness ranging from 200-500 microns through a spray or dip-coating process, for adhering to the enclosure (20).
[0067] The modular panels are reinforced with internal ribs or cross-bracing. High-temperature silicone gaskets and seals are provided in the modular panel to ensure airtight and watertight joints. The thermal insulation materials such as ceramic fibre boards or mineral wool is provided for additional thermal protection and for reducing the heat transfer. The design of the enclosure (20) includes both passive ventilations, with vents and louvers coated with heat-reflective material to facilitate natural airflow and internal insulation for minimizing heat transfer from the external environment to the interior. Both the ventilations protect the sensitive components in the system. The heat reflective coating further provides resistance to UV radiation and weathering, thereby preventing the material degradation over time.
[0068] The power source (30) is configured to operate with multiple fuel types. In the preferred embodiment, the system (100) uses a solid oxide fuel cell (SOFC) (32), that can utilize various fuels including natural gas, compressed natural gas (CNG), liquefied petroleum gas (LPG), propane, and Biogas. The solid oxide fuel cell (32) is an energy conversion device that generates electricity through electrochemical reaction. The solid oxide fuel cell (32) from herein afterwards referred as SOFC.
[0069] Referring to Figure 7, 8 and 9, the hydrogen-rich gas is fed into the SOFC (32) where electrochemical reactions occur to generate electricity. The SOFC (32) includes an electrolyte made from a solid ceramic material, such as yttria-stabilized zirconia (YSZ). In the preferred embodiment, zirconia-ceria-and lanthanum gallate-based electrolyte materials are utilized where the electrolyte allows only oxygen ions to pass through it, which is essential for the electrochemical reactions that generate electricity. The anode and cathode are placed on either side of the electrolyte. Referring now to Figure 10 and Figure 11, Nickel-yttria stabilized zirconia (Ni-YSZ) cermet is used as anode in the present SOFC (32). The anode, where the fuel reacts, is usually made from a cermet (ceramic-metal composite), while the cathode, where oxygen reacts, is made from a mixed conductor. In the present embodiment, at the anode, hydrogen reacts with oxygen ions to produce water, electrons, and heat. The oxygen ions are produced at the cathode, where oxygen molecules from the air intake are reduced. The process generates electricity while also producing heat, which can be recycled within the system (100) to maintain optimal operating temperatures.
[0070] The system (100) includes a fuel management system (55) for managing multiple fuel types that utilizes sensors and detectors (not shown in figure) placed at the fuel inlet to analyse the composition of the incoming fuel. The sensors measure critical parameters such as methane concentration, sulphur compounds, and CO2 levels, among others of the incoming fuel. The present system (100) is provided with a pre-configured database that contains detailed properties of various fuels, including natural gas, LPG, CNG, propane, and Biogas. When a new fuel type is detected, the system (100) references this database to identify the fuel and automatically adjusts the pre-processing and reforming parameters to optimize performance. The multi-fuel capability of the power source (30) is achieved through a series of integrated components and processes that ensure optimal performance regardless of the fuel used. Each type of fuel has distinct properties and compositions that require specific pre-processing steps to convert them into a form suitable for the SOFC (32). Natural gas and CNG, primarily consisting of methane, can be directly reformed within the system (100). LPG and propane, which contain heavier hydrocarbons like propane and butane, that needs to be vaporized and reformed. Biogas composed of methane and carbon dioxide with possible impurities like hydrogen sulphide, requires desulfurization and impurity removal to ensure a cleaner fuel stream.
[0071] The fuel management system (55) further includes a reformer for converting the fuels into hydrogen, which is the primary fuel for the SOFC (32). Steam reforming is used for methane-based fuels such as natural gas, CNG, and Biogas, and autothermal reforming, utilizing both steam and oxygen/air, is employed for fuels with higher hydrocarbon content like LPG, Biogas and propane. The reforming processes is carried out by a fuel processor (not shown in figure) capable of adjusting to different fuels and includes pre-heaters and vaporizers for handling LPG, Biogas and propane, desulfurization units for removing sulphur compounds, and flexible reformers for steam and autothermal reforming. The SOFC (32) further includes a blending system (not shown in figure) for mixing different fuels for a consistent fuel composition for the SOFC (32). Specific storage and handling systems are required for each fuel type due to their distinct physical and chemical properties. Natural gas and CNG are stored in pressurized tanks, while LPG and propane are stored in liquid form under pressure. Biogas is stored in low-pressure gas holders or upgraded to a higher methane content and stored similarly to natural gas.
[0072] The stored energy sources comprise electrical energy storage devices such as rechargeable batteries. Energy storage devices store a finite quantity of electrical charge and the amount of charge stored on a particular energy storage device is typically characterized by a charge capacity rating usually expressed in ampere-hours, quantifying the total charge that a fully charged energy storage device is able to deliver to the load requirement.
[0073] Referring again to Figure 1, the battery system (40) is compatible with multiple battery chemistries and is electrically connected to the power source (30). The present system (100) supports the battery chemistries including Lithium-Ion (Li-ion), Lithium Iron Phosphate (LiFePO4), Nickel-Metal Hydride (NiMH), Lead-Acid, Pure Lead Tin (PLT), AGM batteries, VRLA batteries, lead acid gel batteries, lead carbon batteries, lithium titanate batteries and Flow Batteries up to 10 V to 60 V ranges. The battery system (40) includes a battery management system (not shown in figures) for monitoring, balancing, protection, and communication. The battery management system continuously tracks the critical parameters like voltage, current, temperature, and state of charge (SoC) for each battery type. The battery management system balances the charge levels of cells within each battery pack. The battery management system includes safety protocols to prevent overcharging, discharge management/deep discharging, and overheating of the batteries. The battery management system interfaces with the SOFC’s (32) main control unit (35) to coordinate energy flow and switching decisions. The system (100) includes sensors and identification protocols to automatically detect the type of battery connected, with each type registered with specific parameters such as optimal charging voltage and thermal limits. The battery management system includes predefined configuration profiles stored for charging algorithms, voltage thresholds, and safety parameters for each battery chemistry. Upon identification of the battery type, the battery management system loads the appropriate profile to manage the charging and discharging processes effectively.
[0074] The system (100) utilizes different charging algorithms that are used for each battery chemistry to optimize the performance and lifespan. Li-ion and LiFePO4 batteries utilize Constant Current/Constant Voltage (CC/CV) charging methods, for controlling the current and transitioning to constant voltage mode as the battery nears full charge. NiMH batteries use a delta-V method, that monitors the voltage changes to determine the end of the charging cycle. Lead-Acid batteries are charged in multiple stages, including bulk, absorption, and float charging, with the system adjusting the charging current and voltage to prevent overcharging. Flow Batteries are managed by monitoring electrolyte levels and ensuring proper circulation during charging and discharging.
[0075] The battery management system ensures that the discharge rate of the batteries matches the load requirements while staying within the safe operating limits of the battery. During high-power demands, the system (100) draw power from multiple battery types or combine battery output with SOFC (32) power. The battery management system controls active or passive cooling mechanisms to maintain optimal operating temperatures, with continuous monitoring of battery temperature to ensure prompt responses to overheating conditions.
[0076] Further, the charging unit (50) configured in the system (100) is capable of charging the battery system (40) using multiple energy sources including renewable and non-renewable energy sources. Referring to Figure 3, the renewable energy sources include solar, wind energy, solid oxide fuel cell (32) and the non-renewable energy sources include grid/DG sets. In addition, the input energy source further includes grid energy, scavenge power or gen set energy. In an aspect of the invention, the system (100) includes a universal charger (25) capable of identifying the battery type and rating, switching to standby mode when fully charged, and adjusting output voltage and current as required. The system (100) includes a rectiverter (90) with a capacity of 500 W to 2000W to convert DC power to AC power and vice versa, for using both AC and DC energy sources for charging the battery system (40). Rectiverter (90) combines the dual functions of a rectifier and an inverter into a single, compact unit, where both AC and DC power are required. Combining two functions in one unit reduces the need for separate rectifiers and inverters, saving space and simplifying system architecture. Rectiverters (90) support redundant configurations, ensuring high reliability and availability of power. They can continue to operate even if one module fails, making them suitable for critical applications. The Rectiverter (90) has three ports - one AC input, one AC output and one bidirectional DC port for both input and output. The AC input is first rectified, then fed to a built-in inverter for AC output. The rectified AC input is fed to a DC/DC converter for appropriate DC load output, and to batteries for charging. In case of AC (mains) failure, the DC flow is reversed from the batteries to feed the inverter for conversion to AC, and to take over the DC load. The transition from AC to DC feed is instantaneous and with no load disturbance.
[0077] The system (100) features a plug-and-play architecture for connecting the system (100) to any DC source, such as solar PV, solid oxide fuel cells (32), standalone batteries, and wind power and enabling connection to any AC source such as grid and generator sets.
[0078] In addition, the system (100) includes a power management system (not shown in figures) for managing different energy outputs for switching between DC and AC sources. The power management system includes automatic source detection capabilities, identifying whether the power source (30) is DC, such as from batteries or solar panels, or AC, like from the grid or generators. The detection is achieved through voltage and frequency sensors. Once the source type is identified, the power management system employs conversion modules to match the system requirements. Rectifiers convert incoming AC power to DC, inverters convert DC power to AC when needed, and DC-DC converters adjust the voltage level of DC sources as per requirements.
[0079] The system (100) further includes a control unit (35) configured to manage power distribution based on predetermined priorities for connected devices, including surveillance equipment, sensors, and communication devices (not shown in figure) wherein the control unit (35) includes machine learning algorithms for predicting the operational parameters based on previous data and current inputs in the system (100). Furthermore, the system includes an automatic generator start/stop control system (45) programmable to auto-start/stop the system based on low-voltage, high-demand, or battery state of charge.
[0080] The multiple output configuration unit (90) configured in the system (100) provides electrical power in both AC and DC forms. The AC output is configured to deliver a 230 V pure sinewave and the DC output is configured to deliver voltages of 5, 12, 24, and 48V. The decision-making unit (70) is configured to monitor the load requirements and battery state of charge (SoC) of the system (100) to switch the power source (30) based on a predefined algorithm.
[0081] The present invention includes the fuel container (not shown in figures) that can be installed in the same cabinet and can be exchanged by being swapped out with an HDPE tank or other approved storage that meets industrial standards, the hot swap facility allows to replace the fuel container without the switching off the system (100).
[0082] The fuel tank can be interconnected with stainless steel conduit piping with valve protection. The fuel tank can be cascaded in one or more quantities to increase endurance.
[0083] In an aspect of the invention, the hybrid energy management system (100) is configured with Direct Current (DC) and exchanges DC with the connected subsystem. The system (100) can also be configured with an Alternate Current (AC) for exchanging the DC as well as AC to the connected power system. The system (100) may include one or more power converters disposed between the device port and bus bar. The power converter may include DC to DC up (boost) and DC to DC down, buck voltage converters, voltage stabilizers, or linear voltage regulators, AC to AC up and down voltage converters, voltage regulators, voltage transformers, etc. DC to AC up and down voltage inverter, AC to DC up and down voltage rectifier, AC up and down frequency converter, and other power converting elements suitable to establish an energy network. The power converting circuit may use the power converter, including both boost (step-up) and buck (step-down) voltage converting circuits using switching MOSFET bridges.
[0084] In an aspect of the invention, the step of generating an error signal, warning, or information in visual, text, and log format on the spot or based on data storage for analysis and action is performed. Further system (100) includes the method of calculating the total energy available, which involves calculating both the total average energy and the total peak energy and the step of allocating the total available energy to the energy allocation interface, taking into account both the total average energy and the total peak energy. The method further can include selecting the energy source with the highest source priority for connection to the bus bar, disconnecting any remaining energy sources from the bus bar, and powering all of the connected power loads to the bus bar with the energy source having the highest source priority. Additionally, the method can include merging one or more disconnected energy sources based on pre-defined logic as per requirements.
[0085] In an aspect of inventions, the hybrid energy management system includes a data processing device and associated memory devices. The data processing devices includes a central processing unit (CPU), an integrated microprocessor, a microcontroller, and field programable logic controller (PLC).
[0086] In an aspect of the invention, an energy network is operated by connecting multiple substantially identical hybrid energy management systems on a single platform using available networks, which may be wired, wireless, optical fibre, or satellite. Information about each hybrid energy management system is stored in a smart database for future analysis, which includes details such as device type, device ID (e.g., MAC address), network protocol address (e.g., IP address), logging data specifications, energy information (AC & DC), system (100) running information, GPS-based system location, fuel availability, and hours running details. The communication protocols incorporated in the invention include CAN Bus (Controller Area Network), Ethernet/IP, Wired/Wireless Communication.
[0087] Additionally, the hybrid energy management system (100) is designed for portability, especially for use in man-portable or backpack applications, with each element weighing less than 20 kg, adhering to high-altitude area norms for easy transport in field conditions. The system (100) includes a user interface module and indicator lights for each device, configured for ergonomic use and reliable performance. To prevent power interruptions to mission-critical devices, the hybrid energy management system (100) is connected to two or more energy sources at all times.
[0088] The system (100) operates by connecting one source to the power bus bar at a time while keeping a second source in reserve, which is automatically connected when the power demand exceeds the capacity of the single source. Furthermore, each power device in the system (100) can be assigned a device-specific power priority setting. This setting is used by the system (100) to allocate available power, prioritizing mission-critical devices. Devices with higher power priority are given precedence, while those with lower priority may be switched off if the available power is insufficient to meet instantaneous demands. Power priorities can vary based on the mission requirements and can be updated across multiple devices through the energy management system (100) to save time.
[0089] The system (100) design also incorporates a pressure regulator, sensors, fuel monitoring, pressure gauge, valves, and provides details on flow rate and consumption.
[0090] Referring to Figure 4, a method (200) describing the predefined algorithms for the decision-making unit (70) is provided.
[0091] The method (200) starts at step 210.
[0092] At step 220, the current load requirements of the system (100) are monitored and compared against a predefined load threshold. The predefined load thresholds are the electrical load levels at which the system (100) automatically activates the additional power sources (30) to meet the demand or deactivate the power sources (30) for conserving energy.
[0093] At step 230, the battery state of charge (SoC) of the system is assessed to determine if the charge falls below a critical level.
[0094] At step 240, the power source (30) activation is prioritized based on the availability of renewable sources before non-renewable sources.
[0095] At step 250, the power source (30) is adjusted to maintain an optimal battery state of charge (SoC) to ensure continuous power supply.
[0096] At step 260, a priority protocol is implemented to switch the power sources ON in response to the load increases or low battery state of charge SoC, while delaying power source (30) deactivation to prevent power interruptions.
[0097] At step 270, the components including the power source (30), the battery system (40), the charging unit (50), the multiple output configuration unit (60), the decision-making unit (70), and a virtual switch (80) in the system (100) are initialized and started by identifying the connected battery type and by loading the appropriate battery management profile.
[0098] At step 280, the voltage, current, and temperature of the system is then monitored continuously.
[0099] At step 290, regular checking of the battery state of charge (SoC) of the system is done.
[00100] At step 300, the charging process and balancing of the cells within each battery type is managed.
[00101] At step 310, the power is supplied to the load as needed based on the battery state of charge (SoC) of the system.
[00102] The method (200) ends at step 320.
[00103] The decision-making unit includes the virtual switch (80) embedded in a software for switching the power source (30) ON and OFF based on at least one user-defined conditions including battery state of charge and/or availability of renewable energy sources.
[00104] Referring to Figure 5, a method (400) describing the user-defined conditions for switching the power source (30) ON and OFF is provided.
[00105] The method (200) starts at step 410.
[00106] At step 420, the battery state of charge (SoC) is detected if the battery level is falling below a predetermined threshold.
[00107] At step 430, an increase in load demand above a predefined level is then identified.
[00108] At step 440, the use of renewable energy sources when available is prioritized and a reserve power level for critical operations is maintained.
[00109] At step 450, the over-discharge of batteries is prevented by switching to an alternative power source (30).
[00110] At step 460, the backup power sources (30) are activated when primary power sources fail.
[00111] At step 470, the power source (30) activation based on time-of-day or operational requirements is scheduled and
[00112] At step 480, the power source (30) transitions are manged to avoid disruptions during sensitive operations.
[00113] At step 490, the battery power is switched if the load is less than 20% of the solid oxide fuel cell (32) capacity to avoid inefficiencies.
[00114] At step 500, the solid oxide fuel cell (32) and battery power are combined if the load exceeds 80% of the solid oxide fuel cell (32) capacity.
[00115] At step 510, the battery usage of the system (100) is prioritized if the battery state of charge is high which is greater than 80%.
[00116] At step 520, charging the battery using solid oxide fuel cell (32) power is prioritized if the battery state of charge is low which is less than 20%.
[00117] The method (400) ends at step 530.
[00118] Referring to Figure 6, a method (600) describing the priority protocol as described in step 260 is provided.
[00119] The method (200) starts at step 610.
[00120] At step 620, the additional power sources (30) are switched ON when the load demand exceeds a predefined threshold.
[00121] At step 630, the backup power sources (30) are activated when the battery state of charge (SoC) falls below a critical level to prevent power outages.
[00122] At step 640, the active power sources (30) are maintained for a minimum period after load demand decreases to avoid frequent switching and power interruptions.
[00123] At step 650, the power sources (30) are deactivated based on decreasing load demand and battery state of charge (SoC) is recovered to ensure continuity of power supply.
[00124] At step 660, the load requirements and the battery state of charge are continuously monitored.
[00125] At step 670, the battery power is switched if the load is less than 20% of the fuel cell capacity to avoid inefficiencies.
[00126] At step 680, the solid oxide fuel cell (32) and the battery power are combined if the load exceeds 80% of the solid oxide fuel cell (32) capacity.
[00127] At step 690, the battery usage of the system (100) is prioritized if the battery state of charge is high which is greater than 80%.
[00128] At step 700, charging the battery using solid oxide fuel cell (32) power is prioritized if the battery state of charge is low which is less than 20%.
[00129] The method (600) ends at step 710.
[00130] Referring to Figure 12, the test results indicating the system’s (100) resilience to environmental factors such as temperature extremes, moisture, dust, physical impacts, operation in high altitudes is provided. validated according to the IEC and military standards IEC-62282 & IEC-60068, MIL-STD-810G and MIL-STD-461G. For altitude, tests under MIL-STD-810G Method 500.6, including Procedures I (Storage/Air transportation), II (Operation/Air Carriage), and III (Rapid decompression), confirm the capability of the system to operate effectively in varying atmospheric pressures and rapid decompression scenarios. Temperature resilience is verified through MIL-STD-810G Methods 501.7 and 502.7, covering storage (Procedure I), tactical standby to operational transitions (Procedure III), operational conditions (Procedure II), and manipulation scenarios (Procedure III). The durability of the system against solar radiation, humidity, and salt fog is confirmed through MIL-STD-810G Methods 505.7 (Procedure II), 507.6 (Procedure II), and 509.7, respectively, ensuring sustained performance under prolonged exposure to these elements.
[00131] Further, shock and vibration resilience are validated via MIL-STD-810G Methods 516.8 and 514.8. Shock tests include functional assessment (Procedure I), transportation (Procedure II), and transit drops (Procedure IV). Vibration tests simulate loose cargo transportation (Procedure II) and aircraft store capture carriage and free flight (Procedure IV). Dust and sand exposure are tested under MIL-STD-810G Method 510.7, Procedures I and II, confirming system functionality in particulate-laden environments. The system’s capability to withstand rain, including blowing rain for 30 minutes and its impact on electrical components, is tested under MIL-STD-810G Method 506.6.
[00132] Furthermore, electromagnetic interference and compatibility (EMI/EMC) are rigorously assessed following MIL-STD-461G (CE-101, RE-102, RS-103, CS-114, CS-116) standards, ensuring the system's resilience to various EMI conditions across a wide frequency range. Electrostatic discharge resilience is tested under MIL-STD-461C. Icing and freezing rain conditions are validated using MIL-STD-810G Method 521.4, while freeze/thaw cycles, including diurnal effects, fogging transitions, and rapid temperature changes, are tested under MIL-STD-810G Method 524.1. Combined environmental effects are evaluated through MIL-STD-810G Method 520.5, focusing on engineering design robustness. Performance tests per IEC 62282-7-2 standards, including rated power tests, current-voltage characteristics, effective fuel utilization, long-term durability, thermal cycling durability, internal reforming performance, and resistance component identification, further underscore the system’s reliability and efficiency. The system (100) includes military-grade connectors (12) with extensions to facilitate quick deployment and connection to a military equipment (15).
[00133] In an aspect of the invention, the hybrid energy management system (100) includes a built-in test facility with sensors for monitoring the health, requirements, voltage, current, and temperature of each type of component, along with built-in protection and a warning system to alert for necessary actions. Additionally, the solar charger features an innovative tracking algorithm that maximizes energy harvest by locking onto the optimum MPPT (Maximum Power Point Tracking). The system (100) also provides a flexible charge algorithm that allows selection of preset charge algorithms or offers full programmability. The system (100) is IP-based and configurable for remote management and monitoring. It includes Ethernet circuitry via broadband radio, microwave radio, and alternate routes via optical fiber-based circuitry. The system (100) also supports firmware upgrades for future development or system enhancements. Furthermore, the system (100) design includes protection against overcurrent, overvoltage, short circuits, reverse polarity, overheating, and ensures no fluctuations or surges in power delivery.
[00134] Thus, the present invention has the advantage of providing a hybrid energy management system (100) that is capable of operating with multiple fuel types and battery chemistries, ensuring compatibility with various energy sources, including renewable and non-renewable sources. The system (100) is designed to withstand extreme environmental conditions, including temperature extremes, high humidity, dust, and physical impacts. Additionally, the system (100) can operate within a wide temperature range, enhancing reliability in diverse climates. The system (100) is user-friendly, lightweight, and portable, making it easy to transport and deploy in various locations. Furthermore, the system (100) can be monitored remotely, offering convenience and improved oversight for users. The system (100) is designed for unmanned operation over extended periods, such as days, weeks, months, and beyond, allowing it to function autonomously without human intervention. This feature is essential for applications in remote or hazardous environments where human presence is impractical or dangerous. Additionally, the system (100) is capable of continuous operation for up to 3,000 hours without fluctuations and without requiring maintenance during this period. The system (100) ensures reliability, robustness, compactness, and weight and volume reduction. These features result in better ergonomics, more space for other applications and subsystems, and improved mobility and capability to negotiate gradients.
[00135] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the claims of the present invention.
, C , C , Claims:We Claim:
1. A hybrid energy management system (100) for harvesting, storing, and distributing energy on demand basis, the system (100), comprising:
an enclosure (20) housing the system (100) wherein, the enclosure (20) is a ruggedized enclosure made of cold-rolled close annealed (CRCA) material with a heat reflective coating to withstand extreme environmental conditions;
a power source (30) configured to operate with multiple fuel types;
a battery system (40) compatible with multiple battery chemistries, electrically connected to the power source; and
a charging unit (50) capable of charging the battery system (40) using multiple energy sources including renewable and non-renewable energy sources,
characterized in that, the system (100) includes a multiple output configuration unit (60) providing electrical power in both AC and DC forms, wherein the AC output is configured to deliver a 230 V pure sinewave and the DC output is configured to deliver voltages of 5, 12, 24, and 48V; and
a decision-making unit (70) configured to monitor the load requirements and battery state of charge (SoC) of the system (100) to switch the power source based on a predefined algorithm, wherein the decision-making unit (70) includes a virtual switch (80) embedded in a software for switching the power source ON and OFF based on at least one user-defined conditions including battery state of charge and/or availability of renewable energy sources.
2. The hybrid energy management system (100) as claimed in claim 1, wherein the predefined algorithms for the decision-making unit (70) comprises steps of:
monitoring the current load requirements of the system (100) and comparing the load requirements against a predefined load threshold, wherein the predefined load thresholds are the electrical load levels at which the system (100) automatically activates additional power sources (30) to meet the demand or deactivate the power sources (30) for conserving energy;
assessing the battery state of charge (SoC) of the system (100) to determine if the charge falls below a critical level;
prioritizing the power source (30) activation based on the availability of renewable sources before non-renewable sources;
adjusting the power source (30) to maintain an optimal battery state of charge (SoC) to ensure continuous power supply;
implementing a priority protocol to switch power sources ON in response to load increases or low battery SoC, while delaying power source (30) deactivation to prevent power interruptions;
starting and initializing all components including the power source (30), the battery system (40), the charging unit (50), the multiple output configuration unit (60), the decision-making unit (70), and the virtual switch (80);
identifying the connected battery type and loading the appropriate battery management profile;
monitoring of health, voltage, current, and temperature of the system (100);
checking of the battery state of charge (SoC);
managing the charging process and balancing the cells within each battery type; and
supplying power to the load as needed, based on the battery state of charge (SoC).
3. The hybrid energy management system (100) as claimed in claim 1, wherein the user-defined conditions for switching the power source (30) ON and OFF include:
detecting the battery state of charge (SoC) falling below a predetermined threshold;
identifying an increase in load demand above a predefined level;
prioritizing the use of renewable energy sources when available;
maintaining a reserve power level for critical operations;
preventing the over-discharge of batteries by switching to an alternative power source (30);
activating backup power sources (30) when primary power sources (30) fail;
scheduling power source (30) activation based on time-of-day or operational requirements;
managing power source (30) transitions to avoid disruptions during sensitive operations;
switching to battery power if the load is less than 20% of the solid oxide fuel cell (32) capacity to avoid inefficiencies;
combining solid oxide fuel cell (32) and battery power if the load exceeds 80% of the solid oxide fuel cell (32) capacity;
prioritizing battery usage if the battery state of charge is high (>80%); and
prioritizing charging the battery using solid oxide fuel cell (32) power if the battery state of charge is low (<20%).
4. The hybrid energy management system (100) as claimed in claim 2, wherein the priority protocol comprises:
switching ON additional power sources (30) when the load demand exceeds a predefined threshold;
activating backup power sources (30) when the battery state of charge (SoC) falls below a critical level to prevent power outages;
maintaining active power sources (30) for a minimum period after load demand decreases to avoid frequent switching and power interruptions;
deactivating power sources (30) based on decreasing load demand and recovering battery state of charge (SoC) to ensure continuity of power supply;
continuous monitoring of the load requirements and the battery state of charge;
switching to battery power if the load is less than 20% of the solid oxide fuel cell (32) capacity to avoid inefficiencies;
combining solid oxide fuel cell (32) and battery power if the load exceeds 80% of the solid oxide fuel cell (32) capacity;
prioritizing battery usage if the battery state of charge is high (>80%); and
prioritizing charging the battery using solid oxide fuel cell (32) power if the battery state of charge is low (<20%).
5. The hybrid energy management system (100) as claimed in claim 1, wherein the renewable energy sources including solar, wind energy, Solid Oxide Fuel Cell (SOFC) (32), and the non-renewable energy sources include grid/DG Sets, including energy from where the Solid Oxide Fuel Cell (SOFC) (32) is capable of operating on a variety of fuels, including any natural gas, LPG, propane, and Biogas.
6. The hybrid energy management system as claimed in claim 1, wherein the system (100) includes a plug-and-play architecture for connecting the system (100) to any DC source, such as solar PV, solid oxide fuel cell (32), standalone batteries, and wind power and enabling connection to any AC source such as grid and generator sets.
7. The hybrid energy management system (100) as claimed in claim 1, wherein the system (100) operates within a temperature range of -40°C to +55°C, with storage capabilities from -60°C to +71°C.
8. The hybrid energy management system (100) as claimed in claim 1, wherein the system (100) includes a rectiverter (90) with a capacity of 500 W to convert DC power to AC power and vice versa, for using both AC and DC energy sources for charging the battery system.
9. The hybrid energy management system (100) as claimed in claim 1, wherein the system (100) includes a universal charger (25) capable of identifying the battery type and rating, switching to standby mode when fully charged, and adjusting output voltage and current as required.
10. The hybrid energy management system (100) as claimed in claim 1, wherein the system (100) is capable of operating at altitudes up to 19,000 feet or more.
11. The hybrid energy management system (100) as claimed in claim 1, wherein the battery system (40) includes sensors for monitoring health, voltage, current, temperature, and state of charge (SoC) for each battery type.
12. The hybrid energy management system (100) as claimed in claim 1, wherein the system (100) includes a fuel management system (55) capable of identifying the type of fuel being supplied and a power management system is for handling AC and DC outputs.
13. The hybrid energy management system (100) as claimed in claim 1, wherein the system (100) includes a control unit (35) configured to manage power distribution based on predetermined priorities for connected devices, including surveillance equipment, sensors, and communication devices wherein the control unit (35) includes machine learning algorithms for predicting operational parameters based on previous data and current inputs in the system (100).
14. The hybrid energy management system (100) as claimed in claim 1, wherein the system (100) includes an automatic generator start/stop control system (45) programmable to auto-start/stop the system based on low-voltage, high-demand, or battery state of charge.
15. The hybrid energy management system (100) as claimed in claim 1, wherein the system (100) includes military-grade connectors (12) with extensions to facilitate quick deployment and connection to a military equipment (15).