Electrical power resistors are used in energy generation and distribution, control methods, and other electrical power system purposes. Examples contain load financial institutions, grounding resistors, and dynamic braking resistors.
There are a lot of prospective production techniques but resistors dependent on thick movie technology substrates offer large integration density that tends to make it ideal for programs in which higher energy dissipation is required in a modest area. The content traits of the substrate imply it is an exceptional match with the aluminium materials in heatsinks and it is chemically inert and mechanically steady.
Unique carrier supplies, this kind of as Silicone Nitrite might be utilised to make a power resistor in the kW range. Nonetheless, these components can be costly and might expense as a lot as € two hundred each in get portions of a handful of thousand models, furthermore the costs for processing with Thick Movie materials. This means such components are usually only used for specialists purposes.
Examples include a energy resistor with proportions one hundred mm by 50 mm on one mm thick Alumina Ceramic that can manage five hundred W supplied the element temperature is stored constant at close to 60 °C. Resistor load banks with electrical power scores as substantial as 25 kW @ 140 kVolts may possibly be made.
When produced correctly making use of appropriate components Thick Movie power resistors can deal with a number of kW of power dissipation but they create large quantities of warmth which will fracture the resistor provider plate if not stored underneath manage. Mindful consideration of the application and thermal management is therefore necessary just before committing to the resistor design and production approach.
1 answer to the resistor thermal overload problem is to submerge the electricity resistor in higher grade mineral oil in a warmth exchanger. The exchanger need to be made appropriately to make sure it is capable of removing the heat generated so the oil temperature is retained consistent at a safe degree.
Proper administration of the heat exchanger is essential as Impurities in the sort of carbon deposits are generated in substantial voltage oil cooled techniques and until oil is filtered and / or otherwise kept at large top quality via regular replacements, this kind of impurities will construct to a level exactly where 1 or more resistors are shorted out of the loop and as a result lead to other resistors in the chain to overload and fracture. Yearly oil adjustments are for that reason suggested.
A electrical power resistor made making use of thick film technologies provides a relatively low cost, higher performance, tiny footprint answer for a wide assortment of power apps. However, careful consideration of thermal concerns is needed in the course of the design stage to ensure reputable procedure. Learn more about high power resistors here.