Innovative Liquid-Cooled Resistors for High-Power Applications: EAK Development of Advanced Water-Cooled Resistors

In the realm of high-power electrical systems, the demand for reliable, efficient, and high-performance resistors has never been greater. EAK has pioneered a groundbreaking design in liquid-cooled resistors, specifically optimized for demanding environments such as industrial drives, power conversion systems, and electric vehicle (EV) infrastructure. Our state-of-the-art water-cooled resistor technology combines precision engineering, advanced materials, and innovative cooling techniques to deliver unparalleled performance, safety, and durability.

Cutting-Edge Design and Specifications

Our liquid-cooled resistor series is engineered to meet a broad range of electrical requirements, with resistance values spanning from 10 milliohms to 32 ohms. This extensive resistance range enables applications across various power levels and system configurations. The resistors boast a precision accuracy of 1% to 10%, ensuring consistent electrical characteristics crucial for sensitive power management systems.

One of the standout features of our water-cooled resistors is their exceptionally low temperature coefficient as low as 25 parts per million (PPM). This minimizes resistance drift due to temperature fluctuations, ensuring stable operation over a wide temperature range. The resistors are designed to withstand extreme thermal conditions, making them ideal for high-current, high-voltage environments.

Advanced Cooling Technology

At the core of our resistor design is the integration of IGBT-based dual-sided water cooling technology. This innovative cooling method enables efficient heat dissipation, even under the most demanding operational conditions. The water channel design is meticulously engineered to withstand harsh environments, including high vibration, mechanical shocks, and corrosive conditions, ensuring long-term reliability.

The water-cooling system provides superior thermal management compared to traditional air-cooled resistors, allowing for higher current densities and power ratings without overheating. The water channels are crafted with precision to prevent leaks and facilitate maintenance, while the advanced ceramic insulation treatment guarantees electrical insulation with a withstand voltage exceeding 1500V. This high level of insulation ensures safety and system integrity during operation.

Robust Construction and Reliability

Our high-end welding processes prevent liquid leakage, a critical factor in maintaining electrical safety and system reliability. The resistors feature an inductance-free resistor core design, reducing electromagnetic interference (EMI) and enhancing the overall system performance. The integrated encapsulation technology provides a sealed, compact form factor that resists extreme vibrations and mechanical stresses, making these resistors suitable for installation in rugged environments.

Each resistor unit is designed to handle up to 1000A of current and operate reliably at high voltages of 110kV. The high pulse power capability makes these resistors suitable for applications involving transient overloads, such as power grid stabilization and pulse power systems.

Modular and Scalable Design

Our liquid-cooled resistors are engineered for flexibility and scalability. A single resistor can be configured in parallel or series to achieve power ratings up to 20kW (two 10kW units), enabling water-electrical separation and enhancing insulation safety. This modular approach simplifies system design and maintenance, allowing customization based on specific application requirements.

The superior water-cooling efficiency, combined with the high-precision, low-inductance resistor core, ensures consistent performance under extreme operating conditions. The resistors are ideal for high-voltage direct current (HVDC) systems, electric vehicle (EV) fast charging stations, industrial drives, and renewable energy systems.

Applications and Benefits

  • High-Power Electric Vehicle Charging: Ensuring safe and reliable current limiting during rapid charging cycles.
  • Power Grid Stabilization: Managing transient currents and suppressing voltage fluctuations.
  • Industrial Power Supplies: Providing precise resistance control in demanding manufacturing environments.
  • Renewable Energy Systems: Facilitating energy dissipation and system protection in solar and wind power installations.
  • Pulse Power Systems: Handling high pulse currents with excellent thermal and electrical stability.

Why Choose Our Liquid-Cooled Resistors?

  • Exceptional Thermal Management: Dual-sided water cooling technology ensures efficient heat dissipation, enabling higher power densities.
  • Superior Electrical Performance: Low resistance, high precision, and low inductance design guarantee system stability.
  • Robust Construction: Advanced ceramic insulation, high-end welding, and sealed encapsulation resist environmental stressors.
  • High Voltage and Current Ratings: Capable of withstanding up to 110kV and 1000A, suitable for the most demanding applications.
  • Modular and Scalable: Configurable for varied power requirements with multiple units in series or parallel.
  • Safety and Reliability: Water-electrical separation and high insulation withstand voltages ensure operational safety.

Conclusion

EAK’s innovative liquid-cooled resistors exemplify the pinnacle of high-power resistor technology. Combining water cooling, advanced insulation, and robust construction, these resistors are designed to operate reliably in the most challenging environments. Whether for high-voltage power systems, electric vehicle infrastructure, or industrial applications, our water-cooled resistors deliver unmatched performance, safety, and longevity.

For more information or to customize a solution tailored to your specific needs, contact our technical team today. Experience the future of high-power resistors with EAK’s advanced liquid-cooled resistor technology—where innovation meets reliability.

https://www.eak.sg/blogs/advanced-liquid-cooled-resistor-for-high-power-applications-eak-innovation/


 

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