IP Library Granted Patent US 12,355,236
Granted Patent B2
US 12,355,236 · App. 18/922,947 · Granted Jul 8, 2025

Systems and methods for fault tolerant energy management systems configured to manage heterogeneous power plants

Inventors: Shaheen Fakhar (Herndon, VA); Christian Chia Wang (Philadelphia, PA); Robert Jordan Toth (Leesburg, VA); Andrew Robert Beyer (Aldie, VA)
Assignee: Energy Vault, Inc.
H02J13/00
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Quick Facts
Patent No.
US 12,355,236
App. No.
18/922,947
Granted
Jul 8, 2025
Kind
B2
Abstract

An energy management system and methods of using the same are disclosed. The energy management system is configured to distribute power plant tasks. Energy management system tasks are received at the energy management system. At least a portion of the received tasks are passed over a network from the energy management system to a power plant lead controller in a cluster of nodes, the cluster of nodes comprising electronic devices configured to control power plant equipment, the cluster of nodes comprising the power plant lead controller and a plurality of power plant follower controllers, the cluster of nodes configured to provide a plurality of combinations of redundancy to control power plant equipment. The power plant lead controller delegates, in real time, tasks to the plurality of power plant follower controllers. At least one of the cluster of nodes is configurable to be in hot standby mode.

Claims (37)

1. A computer-implemented method of distributing tasks at a power plant, the method comprising:

distributing, by an energy management system configured to control components of a power plant to manage power output to a power grid, a control function across multiple nodes in a cluster of nodes, the cluster of nodes comprising electronic devices configured to control power plant components and configured to provide a plurality of combinations of redundancy to control power plant components, the cluster of nodes comprising at least a first node, a second node and a third node;

designating, by the energy management system, the first node in the cluster of nodes as a lead controller, wherein the second node and the third node are designated as follower controllers;

receiving energy management system tasks at the energy management system;

passing at least a portion of the received tasks over a network from the energy management system to the first node in the cluster of nodes, the first node configured as the lead controller;

delegating, in real time, by the first node configured as the lead controller, tasks, comprising at least a portion of the received tasks, to other nodes, configured as follower controllers, in the cluster of nodes;

at least partly in response to detecting that the first node, configured as the lead controller, in the cluster of nodes is unavailable, executing a failover process comprising a cluster voting process, wherein nodes in the cluster of nodes vote for a new lead controller; and

based at least in part on the voting process, enable the second node in the cluster of nodes to be designated as lead controller.

2. The computer-implemented method as defined in claim 1 , wherein the voting process comprises a Raft consensus voting process, a Paxos consensus voting process, a Multi-Paxos consensus voting process, a Bully voting process, a ZooKeeper Atomic Broadcast (ZAB) voting process, and/or a quorum-based voting process.

3. The computer-implemented method as defined in claim 1 , wherein at least one node in the cluster of nodes at least partly bases its vote on a location of at least one other node.

4. The computer-implemented method as defined in claim 1 , wherein at least one node in the cluster of nodes at least partly bases its vote on a communication latency.

5. The computer-implemented method as defined in claim 1 , wherein at least one node in the cluster of nodes casts its vote to enhance load balancing.

6. The computer-implemented method as defined in claim 1 , wherein at least one node of the cluster of nodes is cloud-based.

7. The computer-implemented method as defined in claim 1 , wherein at least one node of the cluster of nodes is located at a second power plant.

8. The computer-implemented method as defined in claim 1 , wherein one or more power plant follower controllers comprise a server and/or microcontrollers configured with real time operating systems.

9. The computer-implemented method as defined in claim 1 , the method further comprising using cascading commands to propagate commands or actions from one node in the cluster to other nodes in a cascading manner.

10. The computer-implemented method as defined in claim 1 , wherein the energy management system comprises a node configured to operate as a backup to the first node.

11. A system, comprising:

an energy management system comprising one or more computing devices, the energy management system configured to distribute a control function across multiple nodes in a cluster of nodes, the cluster of nodes comprising a plurality of nodes comprising electronic devices configured to control power plant equipment and configured to provide a plurality of combinations of redundancy to control power plant equipment,

the plurality of cluster nodes comprising:

at least a first cluster node designated as a lead controller, and a least a second cluster node and a third cluster node designated as follower controllers;

wherein the system is configured to:

receive energy management system tasks using the energy management system;

pass at least a portion of the received tasks over a network from the energy management system to the first node in the cluster of nodes, the first node configured as the lead controller;

delegate, in real time, using the first node configured as the lead controller, tasks, comprising at least a portion of the received tasks, to other nodes, configured as follower controllers, in the cluster of nodes;

at least partly in response to at least one follower controller detecting that the first node, configured as the lead controller, in the cluster of nodes is unavailable, execute a failover process comprising a cluster voting process, wherein nodes in the cluster of nodes vote for a new lead controller; and

based at least in part on the voting process, enable the second node in the cluster of nodes to be designated as lead controller.

12. The system as defined in claim 11 , wherein the voting process comprises a Raft consensus voting process, a Paxos consensus voting process, a Multi-Paxos consensus voting process, a Bully voting process, a ZooKeeper Atomic Broadcast (ZAB) voting process, and/or a quorum-based voting process.

13. The system as defined in claim 11 , wherein at least one node in the cluster of nodes at least partly bases its vote on a location of at least one other node.

14. The system as defined in claim 11 , wherein at least one node in the cluster of nodes at least partly bases its vote on a communication latency.

15. The system as defined in claim 11 , wherein at least one node in the cluster of nodes casts its vote to enhance load balancing.

16. The system as defined in claim 11 , wherein at least one node of the cluster of nodes is cloud-based.

17. The system as defined in claim 11 , wherein at least one node of the cluster of nodes is located at a second power plant.

18. The system as defined in claim 11 , wherein one or more power plant follower controllers comprise a server and/or microcontrollers configured with real time operating systems.

19. The system as defined in claim 11 , wherein the cluster of nodes is configured to use cascading commands to propagate commands or actions from one node in the cluster to other nodes in a cascading manner.

20. The system as defined in claim 11 , wherein the energy management system comprises a node configured to operate as a backup to the first node.

21. The system as defined in claim 11 , wherein the energy management system is located at a second power plant.

Assignments (4)
SECURITY INTEREST Recorded Jul 9, 2026
From: ENERGY VAULT HOLDINGS, INC.; ENERGY VAULT, INC.
To: YA II PN, LTD.
Reel/Frame 075951/0438 →
RELEASE OF SECURITY INTEREST Recorded Jul 21, 2025
From: CRESCENT COVE OPPORTUNITY LENDING, LLC
To: ENERGY VAULT, INC.
Reel/Frame 072107/0027 →
SECURITY INTEREST Recorded May 13, 2025
From: ENERGY VAULT, INC.
To: CRESCENT COVE OPPORTUNITY LENDING, LLC
Reel/Frame 071269/0676 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 14, 2025
From: FAKHAR, SHAHEEN; WANG, CHRISTIAN CHIA; TOTH, ROBERT JORDAN; BEYER, ANDREW ROBERT
To: ENERGY VAULT, INC.
Reel/Frame 070522/0182 →
Continuity (3)
Continuation In Part 18473579 · Sep 25, 2023
Provisional Application 63518283 · Aug 8, 2023
Related Publication 20250055312A1 · Feb 13, 2025
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