Electrical power resistors are employed in electricity era and distribution, control methods, and other energy method applications. Examples contain load banks, grounding resistors, and dynamic braking resistors.
There are a lot of possible production methods but resistors primarily based on thick film technologies substrates provide high integration density that helps make it ideal for programs the place higher electricity dissipation is necessary in a little location. The materials characteristics of the substrate imply it is an excellent match with the aluminium content in heatsinks and it is chemically inert and mechanically steady.
Unique provider components, this kind of as Silicone Nitrite may be utilised to produce a energy resistor in the kW range. Nonetheless, these resources can be costly and may cost as considerably as € 200 each in purchase quantities of a handful of thousand units, additionally the expenses for processing with Thick Movie materials. This means such materials are usually only used for experts purposes.
Illustrations contain a energy resistor with dimensions a hundred mm by fifty mm on one mm thick Alumina Ceramic that can handle 500 W supplied the factor temperature is kept continual at about 60 °C. Resistor load banking companies with electrical power rankings as higher as twenty five kW @ a hundred and forty kVolts may possibly be made.
When manufactured accurately making use of appropriate materials Thick Movie electricity resistors can take care of numerous kW of electrical power dissipation but they produce huge quantities of heat which will fracture the resistor carrier plate if not held below handle. Careful thought of the application and thermal management is as a result required before committing to the resistor design and production approach.
One solution to the resistor thermal overload problem is to submerge the power resistor in high grade mineral oil in a heat exchanger. The exchanger ought to be made appropriately to make sure it is capable of taking away the warmth generated so the oil temperature is stored continual at a secure amount.
Appropriate management of the heat exchanger is needed as Impurities in the type of carbon deposits are produced in high voltage oil cooled techniques and except if oil is filtered and / or or else kept at higher high quality through standard replacements, this kind of impurities will develop to a amount the place a single or a lot more resistors are shorted out of the loop and for that reason lead to other resistors in the chain to overload and fracture. Yearly oil adjustments are as a result suggested.
A electricity resistor produced employing thick movie technologies supplies a reasonably minimal price, higher functionality, small footprint resolution for a wide range of energy apps. Nevertheless, careful consideration of thermal concerns is essential for the duration of the design period to make certain reputable procedure. Learn more about power resistor here.