EP0604481B1 - Liquid-cooled heavy-duty resistor - Google Patents

Liquid-cooled heavy-duty resistor Download PDF

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Publication number
EP0604481B1
EP0604481B1 EP92918785A EP92918785A EP0604481B1 EP 0604481 B1 EP0604481 B1 EP 0604481B1 EP 92918785 A EP92918785 A EP 92918785A EP 92918785 A EP92918785 A EP 92918785A EP 0604481 B1 EP0604481 B1 EP 0604481B1
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EP
European Patent Office
Prior art keywords
liquid
resistor
duty
resistor element
insulating
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EP92918785A
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German (de)
French (fr)
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EP0604481A1 (en
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Alfred Bochtler
Rolf Neubert
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Siemens AG
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Siemens AG
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C1/00—Details
    • H01C1/08—Cooling, heating or ventilating arrangements
    • H01C1/082—Cooling, heating or ventilating arrangements using forced fluid flow
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C3/00—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids
    • H01C3/02—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids arranged or constructed for reducing self-induction, capacitance or variation with frequency

Definitions

  • the invention relates to a liquid-cooled high-load resistor.
  • a liquid-cooled power resistor is known from EP 0 066 902 B1.
  • This liquid-cooled power resistor consists of a cylindrical housing with two flanges. This housing is closed at the end with an upper cover plate and a lower cover plate. The flanges are cuboid in shape so that their corners protrude from the cylinder and are used for connection to the cover plates by means of fastening screws.
  • the closed housing is provided with two connections for deionized water, an inlet hole being provided in the lower connection and an outlet hole being provided in the upper connection.
  • Four panels are attached to the inside of the housing. They alternately leave a flow cross-section on the left and right and serve to deflect the deionized water.
  • the screens are also used as holders for the resistance conductor.
  • the upper and lower cover plates are each provided with a connecting pin and fixed with a nut. The resistance conductor is connected to these connection pins.
  • the cylinder with the flanges are made of aluminum and the cover plates are made of polypropylene. The deionized water used as coolant runs through the power resistor and is continuously treated in bypass operation.
  • this liquid-cooled power resistor still has a high inductance.
  • its resistance value is relatively high, for example 10 ⁇ to 100 ⁇ .
  • a liquid-cooled resistor which consists of a hollow body and a resistance carrier arranged in its interior. This resistance carrier is wound with resistance wire.
  • the hollow body and the resistance body consist of insulating material and are spaced apart from one another by an intermediate space forming a cooling channel. Which is connected to a coolant inflow to the lower end of the hollow body and to a coolant outflow at the upper end of the hollow body.
  • the resistance carrier consists of a rod-shaped body with radially arranged arms on which the resistance wire is wound bidirectionally. The ends of the resistance wire are each connected to an electrical connection.
  • Such a liquid-cooled resistor has a low inductance and can dissipate a high power loss.
  • it is disadvantageous that such resistors have a low insulating strength and the cooling liquid may not be electrically conductive. Due to the use of a thin wire as a resistance conductor, the resistance value of such a liquid-cooled resistor is very large.
  • the invention is based on the object of specifying a liquid-cooled high-load resistor which can dissipate a high power loss in a small space, is low-inductance and has a very low resistance value.
  • the chamber consists of two insulating plates and an insulating ring and that a bifilar wound conductor strip spiral is provided as a resistance element, which is stretched between the two insulating plates in such a way that the coolant flows through a rectangular channel.
  • the resistance element By arranging the resistance element directly in the cooling liquid, as a result of which the cooling liquid flows along the current-carrying resistance element, a high power loss can be dissipated to the cooling liquid.
  • the resistance element By designing the resistance element as a bifilar wound conductor strip spiral, the resulting inductance of the high-load resistor is kept to a minimum, with a flat strip being chosen as the resistance material, which, due to the geometry, has a low self-inductance compared to a round conductor.
  • the conductor strip of the resistance element is provided with an insulating layer. Ceramic material with which the conductor strip is coated can be provided as the insulating layer. It is therefore also possible to use conductive cooling liquid, for example service water, as the cooling liquid. Oil can also be used as a coolant. If the conductor strip of the resistance element is not insulated, deionized water is used as the cooling liquid.
  • the resistance element is mechanically fixed by means of knobs on at least one insulating plate.
  • These knobs are made of electrically non-conductive material, for example plastic. This simplifies the Assembly of the individual parts to form a high-load resistor and the resistance spiral has a uniform slope along the resistance flat strip, as a result of which a channel formed along the flat strip has a uniform cross section.
  • Another embodiment of the mechanical fixing of the resistance element is a bifilar groove in an insulating plate of the high-load resistor.
  • an insulating plate and an insulating ring of this high-load resistor form one design. This considerably simplifies the assembly, because the resistance element is first installed in the chamber of the high-load resistor and in a subsequent operation, this pre-assembled high-load resistor can be closed in a liquid-tight manner by means of the second insulating plate. By using a structural unit, only one sealing ring is required.
  • the space requirement for such a high-load resistor is small.
  • the resistance value can be adjusted by changing the length, the width or the thickness of the strip material. For an existing construction of the housing, the variation of the conductor strip thickness is appropriate.
  • the power loss to be dissipated is determined with the amount of liquid flowing through per unit of time.
  • the high-load resistor according to the invention Possibility to flow around the conductor tape spiral once or twice.
  • the coolant flows from the inlet to the center of the high-load resistor - the turning point of the bifilar wound conductor strip spiral - and back to the outlet.
  • a further inlet and outlet are arranged in the turning area of the bifilar wound conductor strip spiral. This creates two parallel cooling channels that can be flowed through in the same direction or in opposite directions with cooling liquid.
  • twice the amount of coolant can flow through this high-load resistor per unit of time, which also doubles the power dissipated to the coolant without changing the space requirement of the high-load resistor.
  • FIG. 1 shows a top view of the liquid-cooled high-load resistor according to the invention.
  • This high-load resistor consists of a housing 2 and a resistance element 4, which is shown in more detail in Figure 3.
  • the housing 2 of the high-load resistor consists of a chamber 6, in which the resistance element 4 is arranged, and a cover 8.
  • an insulating plate is provided which is detachably closed with the chamber 6 by means of a circumferential sealing ring 10 in a liquid-tight manner.
  • the cover 8 can also not be detachably connected to the chamber 6.
  • the chamber 6 consists of an insulating plate 12 and an insulating ring 14.
  • the corners of the insulating ring 14 are designed as flanges or fastening tabs 16.
  • the insulating plate 12, which forms the bottom of the chamber 6, is likewise closed in a liquid-tight manner by means of a circumferential sealing ring.
  • the insulating ring 14 and the insulating plate 12 form a structural unit.
  • Knobs 18 made of electrically non-conductive material are provided for mechanically fixing the resistance element 4 on the insulating plate 12. These knobs 18 are alternately inserted on both sides along imaginary radial lines on the insulating plate 12. Deflection pins 20 and 22 are arranged in the interior of the resistance element 4, which are shown in FIG. 6 below. The electrical connections 24 and 26 of the resistance element 4 are arranged in the edge region of the chamber 6. Also in the edge region of the chamber 6, an inlet 28 and an outlet 30 for the coolant are arranged in the insulating plate 8.
  • the resistance element 4 is clamped in the chamber 6 by means of the insulating plate 8 and the releasable fastening elements in such a way that the cooling liquid flows through a rectangular channel 32.
  • the resistance element 4 is shown in more detail in FIG.
  • a bifilar wound conductor strip spiral 34 is provided, which is provided with an electrical connection 24 and 26 at its free ends.
  • a stainless steel band with the following dimensions 0.5x10x4,000 mm3 can be provided as the resistance material.
  • the deflection pins 20 and 22 are arranged eccentrically to the center point 40 of the chamber 6 of the high-load resistor. The distance from the center 36 to the center 40 is marked with a and the distance from the center 38 to the center 36 is marked with b. The bending radii of the conductor strip of the resistance element 4 can be determined by means of these distances.
  • a further inlet or a further outlet and in the center 38 can be arranged in addition to the deflecting pin 22, a further outlet or a further inlet.
  • a spiral channel 32 is obtained, through which the coolant always flows in the opposite direction relative to a partition (conductor strip).
  • the coolant By placing the Inlet 28, outlet 30, the further inlet and the further outlet, the coolant can flow in the two channels in the same direction or in the opposite direction.
  • the flow rate of the cooling liquid can be doubled through the second channel, as a result of which the power loss to be dissipated also doubles.
  • the conductor current is supplied and discharged at the electrical connections 24 and 26, the individual spiral paths are flowed through in the opposite direction by the current, as a result of which the resulting inductance of this resistance element 4 is minimal.
  • the resistance material has the form of a flat strip (FIG. 4), which, due to the geometry, has a lower self-inductance than a round conductor.
  • the electrical connection 24 or 26, of which only the connection 26 is shown in FIG. 4, consists of a web 42 which is arranged on a disk 44.
  • a threaded bolt 46 is attached to the side of the disk 44 facing away from the web 42.
  • the free end of the conductor strip spiral 34 is electrically conductively connected to the web 42.
  • an end face 48 of the web 42 terminates with the insulating ring 14 (chamber wall) and a web side 50 directed towards the inlet of the cooling channel 32 is chamfered so that the cooling liquid can enter and exit as swirl-free as possible.
  • FIG. 5 shows a further sectional illustration III-III according to FIG. 1.
  • This sectional view III-III shows on the one hand an electrical connection 24 and on the other hand the inlet 28 arranged in the insulating plate 8.
  • the electrical connection 24 consists of the parts of web 42, washer 44 and threaded bolt 46 (FIG. 4) and a connecting conductor 52, which is electrically conductively connected to the threaded bolt 46 by means of a nut 54 and a washer 56.
  • the inlet 28 consists of a connection piece 58, which is anchored in the insulating plate 8 in a liquid-tight manner by means of a seal 60.
  • a coolant hose 62 of a cooling system (not shown in any more detail) is plugged onto the connector 58.
  • the cooling liquid flows through the hose 62 and the nozzle 58 into the entrance of the cooling channel 32, the opening of which lies in the sectional plane. That is, the coolant emerges vertically from the drawing plane.
  • FIG. 6 shows a further sectional view IV-IV according to FIG. 1.
  • This illustration shows the deflecting pins 20 and 22 in the middle of the chamber 6 of the high-load resistor.
  • These deflecting pins 20 and 22 each also serve as receptacles for a releasable fastening means 64, with which the bifilar wound conductor strip spiral 34 is also pressed in the chamber 6 in the center of the high-load resistance.
  • this resistor has a resistance value of only 0.8 ⁇ with a load capacity of 5 kW at a flow rate of 3 l / min in the single-channel version.
  • the two-channel embodiment has a load capacity of 10 kW with a flow rate of 6 l / min.

Abstract

PCT No. PCT/DE92/00762 Sec. 371 Date Mar. 21, 1994 Sec. 102(e) Date Mar. 21, 1994 PCT Filed Sep. 8, 1992 PCT Pub. No. WO93/06605 PCT Pub. Date Apr. 1, 1993.A liquid cooled, heavy duty resistor including a housing and a resistor element. The resistor element is arranged inside a chamber defined by the housing. The resistor element and the housing form a rectangular duct through which a cooling liquid flows from an inlet to an outlet. The chamber is defined by two insulating plates and an insulating ring. The resistor element is a bifilar wound spiral strip conductor and is clamped between two insulating plates such that the cooling liquid flows through the rectangular duct. The liquid cooled, heavy duty resistor can remove a high dissipated power in a small space, has low inductance, and has a low resistance value.

Description

Die Erfindung bezieht sich auf einen flüssigkeitsgekühlten Hochlastwiderstand.The invention relates to a liquid-cooled high-load resistor.

Aus der EP 0 066 902 B1 ist ein flüssigkeitsgekühlter Leistungswiderstand bekannt. Dieser flüssigkeitsgekühlte Leistungswiderstand besteht aus einem zylinderförmigen Gehäuse, der mit zwei Flanschen versehen ist. Dieses Gehäuse ist stirnseitig mit einer oberen Deckplatte und einer unteren Deckplatte abgeschlossen. Die Flansche sind in Quaderform ausgebildet, so daß ihre Ecken den Zylinder überragen und zur Verbindung mit den Deckplatten mittels Befestigungsschrauben dienen. Das geschlossene Gehäuse ist mit zwei Anschlüssen für entionisiertes Wasser vorgesehen, wobei im unteren Anschluß eine Eintrittsbohrung und im oberen Anschluß eine Austrittsbohrung vorgesehen sind. Im Inneren des Gehäuses sind vier Blenden befestigt. Sie lassen wechselweise links und rechts je einen Durchflußquerschnitt frei und dienen zur Ablenkung des entionisierten Wassers. Sie sind mit Bohrungen versehen, durch die ein Widerstandsleiter serpentinenartig geführt ist. Somit werden die Blenden gleichzeitig als Halterungen für den Widerstandsleiter verwendet. Die obere und untere Deckplatte ist jeweils mit einem Anschlußstift versehen und mittels einer Mutter fixiert. Mit diesen Anschlußstiften ist der Widerstandsleiter verbunden. Bei dieser Ausführungsform des flüssigkeitsgekühlten Leistungswiderstandes bestehen der Zylinder mit den Flanschen aus Aluminium und die Deckplatten aus Polypropylen. Das als Kühlflüssigkeit verwendete entionisierte Wasser läuft durch den Leistungswiderstand und wird im Bypassbetrieb dauernd aufbereitet.A liquid-cooled power resistor is known from EP 0 066 902 B1. This liquid-cooled power resistor consists of a cylindrical housing with two flanges. This housing is closed at the end with an upper cover plate and a lower cover plate. The flanges are cuboid in shape so that their corners protrude from the cylinder and are used for connection to the cover plates by means of fastening screws. The closed housing is provided with two connections for deionized water, an inlet hole being provided in the lower connection and an outlet hole being provided in the upper connection. Four panels are attached to the inside of the housing. They alternately leave a flow cross-section on the left and right and serve to deflect the deionized water. They are provided with holes through which a resistance conductor is guided like a serpentine. Thus, the screens are also used as holders for the resistance conductor. The upper and lower cover plates are each provided with a connecting pin and fixed with a nut. The resistance conductor is connected to these connection pins. In this embodiment of the liquid-cooled power resistor, the cylinder with the flanges are made of aluminum and the cover plates are made of polypropylene. The deionized water used as coolant runs through the power resistor and is continuously treated in bypass operation.

Durch die direkte Anordnung des Widerstandsleiters in der Kühlflüssigkeit wird eine wirksame und gleichmäßige Wärmeabfuhr gesichert, wobei die Wärmekapazität verhältnismäßig hoch ist. Trotz der serpentinartigen oder mäanderförmigen Anordnung des Widerstandsleiters weist dieser flüssigkeitsgekühlte Leistungswiderstand immer noch eine hohe Induktivität auf. Außerdem ist sein Widerstandswert verhältnismäßig hoch, beispielsweise 10Ω bis 100Ω.The direct arrangement of the resistance conductor in the cooling liquid makes it effective and uniform Heat dissipation ensured, the heat capacity is relatively high. Despite the serpentine or meandering arrangement of the resistance conductor, this liquid-cooled power resistor still has a high inductance. In addition, its resistance value is relatively high, for example 10Ω to 100Ω.

Aus der DE 36 39 239 A1 ist ein flüssigkeitsgekühlter Widerstand bekannt, der aus einem Hohlkörper und einem in seinem Innenraum angeordneten Widerstandsträger besteht. Dieser Widerstandsträger ist mit Widerstandsdraht bewickelt. Der Hohlkörper und der Widerstandskörper bestehen aus Isoliermaterial und sind durch einen einen Kühlkanal bildenden Zwischenraum voneinander beabstandet. Der ans untere Ende des Hohlkörpers mit einem Kühlmittelzufluß und am oberen Ende des Hohlkörpers mit einem Kühlmittelabfluß in Verbindung steht. Der Widerstandsträger besteht aus einem stabförmigen Körper mit radial angeordneten Armen, auf denen der Widerstandsdraht bidirektional aufgewickelt ist. Die Enden des Widerstandsdrahtes sind jeweils mit einem elektrischen Anschluß verbunden. Ein derartig flüssigkeitsgekühlter Widerstand hat eine geringe Induktivität und kann eine hohe Verlustleistung abführen. Nachteilig ist jedoch, daß derartige Widerstände eine geringe Isolierfestigkeit aufweisen und die Kühlflüssigkeit nicht-elektrisch leitend sein darf. Bedingt durch die Verwendung eines dünnen Drahtes als Widerstandsleiter ist der Widerstandswert eines derartigen flüssigkeitsgekühlten Widerstandes sehr groß.From DE 36 39 239 A1 a liquid-cooled resistor is known, which consists of a hollow body and a resistance carrier arranged in its interior. This resistance carrier is wound with resistance wire. The hollow body and the resistance body consist of insulating material and are spaced apart from one another by an intermediate space forming a cooling channel. Which is connected to a coolant inflow to the lower end of the hollow body and to a coolant outflow at the upper end of the hollow body. The resistance carrier consists of a rod-shaped body with radially arranged arms on which the resistance wire is wound bidirectionally. The ends of the resistance wire are each connected to an electrical connection. Such a liquid-cooled resistor has a low inductance and can dissipate a high power loss. However, it is disadvantageous that such resistors have a low insulating strength and the cooling liquid may not be electrically conductive. Due to the use of a thin wire as a resistance conductor, the resistance value of such a liquid-cooled resistor is very large.

Der Erfindung liegt nun die Aufgabe zugrunde, einen flüssigkeitsgekühlten Hochlastwiderstand anzugeben, der auf kleinem Raum eine hohe Verlustleistung abführen kann, niederinduktiv ist und einen sehr geringen Widerstandswert aufweist.The invention is based on the object of specifying a liquid-cooled high-load resistor which can dissipate a high power loss in a small space, is low-inductance and has a very low resistance value.

Diese Aufgabe wird erfindungsgemäß dadurch gelöst, daß die Kammer aus zwei Isolierplatten und einem Isolierring besteht und daß als Widerstandselement eine bifilar gewickelte Leiterbandspirale vorgesehen ist, die derart zwischen den beiden Isolieplatten gespannt ist, daß die Kühlflüssigkeit durch einen rechteckförmigen Kanal strömt.This object is achieved in that the chamber consists of two insulating plates and an insulating ring and that a bifilar wound conductor strip spiral is provided as a resistance element, which is stretched between the two insulating plates in such a way that the coolant flows through a rectangular channel.

Durch die Anordnung des Widerstandselementes direkt in der Kühlflüssigkeit, wodurch beidseitig am stromführenden Widerstandselement die Kühlflüssigkeit entlangströmt, kann eine hohe Verlustleistung an die Kühlflüssigkeit abgeführt werden. Durch die Ausgestaltung des Widerstandselementes als bifilar gewickelte Leiterbandspirale wird die resultierende Induktivität des Hochlastwiderstandes mimimal gehalten, wobei als Widerstandsmaterial ein Flachband gewählt ist, welches aufgrund der Geometrie im Vergleich zu einem Rundleiter eine niedrige Eigeninduktivität aufweist.By arranging the resistance element directly in the cooling liquid, as a result of which the cooling liquid flows along the current-carrying resistance element, a high power loss can be dissipated to the cooling liquid. By designing the resistance element as a bifilar wound conductor strip spiral, the resulting inductance of the high-load resistor is kept to a minimum, with a flat strip being chosen as the resistance material, which, due to the geometry, has a low self-inductance compared to a round conductor.

In einer bevorzugten Ausführungsform ist das Leiterband des Widerstandselementes mit einer Isolierschicht versehen. Als Isolierschicht kann keramisches Material vorgesehen sein, mit dem das Leiterband beschichtet wird. Somit kann man als Kühlflüssigkeit auch leitfähige Kühlflüssigkeit verwenden, beispielsweise Brauchwasser. Ebenso kann man Öl als Kühlflüssigkeit verwenden. Ist das Leiterband des Widerstandselementes nicht isoliert, wird als Kühlflüssigkeit entionisiertes Wasser verwendet.In a preferred embodiment, the conductor strip of the resistance element is provided with an insulating layer. Ceramic material with which the conductor strip is coated can be provided as the insulating layer. It is therefore also possible to use conductive cooling liquid, for example service water, as the cooling liquid. Oil can also be used as a coolant. If the conductor strip of the resistance element is not insulated, deionized water is used as the cooling liquid.

Das Widerstandselement wird in einer bevorzugten Ausführungsform des Hochlastwiderstandes mittels Noppen auf wenigstens einer Isolierplatte mechanisch fixiert. Diese Noppen sind aus elektrisch nicht leitendem Material, beispielsweise Kunststoff. Dadurch vereinfacht sich der Zusammenbau der einzelnen Teile zum Hochlastwiderstand und die Widerstandsspirale weist entlang des Widerstands-Flachbandes eine gleichmäßige Steigung auf, wodurch ein gebildeter Kanal entlang des Flachbandes einen gleichmäßigen Querschnitt aufweist.In a preferred embodiment of the high-load resistor, the resistance element is mechanically fixed by means of knobs on at least one insulating plate. These knobs are made of electrically non-conductive material, for example plastic. This simplifies the Assembly of the individual parts to form a high-load resistor and the resistance spiral has a uniform slope along the resistance flat strip, as a result of which a channel formed along the flat strip has a uniform cross section.

Eine weitere Ausführungsform der mechanischen Fixierung des Widerstandselementes ist eine bifilar geführte Nut in einer Isolierplatte des Hochlastwiderstandes.Another embodiment of the mechanical fixing of the resistance element is a bifilar groove in an insulating plate of the high-load resistor.

Bei einer besonders vorteilhaften Ausführungsform des Hochlastwiderstandes bildet eine Isolierplatte und ein Isolierring dieses Hochlastwiderstandes eine Bauform. Dadurch vereinfacht sich der Zusammenbau erheblich, weil das Widerstandselement zunächst in die gebildete Kammer des Hochlastwiderstandes montiert werden und in einem anschließenden Arbeitsgang dieser vormontierte Hochlastwiderstand mittels der zweiten Isolierplatte flüssigkeitsdicht verschlossen werden kann. Durch die Verwendung einer Baueinheit wird auch nur noch ein Dichtring gebraucht.In a particularly advantageous embodiment of the high-load resistor, an insulating plate and an insulating ring of this high-load resistor form one design. This considerably simplifies the assembly, because the resistance element is first installed in the chamber of the high-load resistor and in a subsequent operation, this pre-assembled high-load resistor can be closed in a liquid-tight manner by means of the second insulating plate. By using a structural unit, only one sealing ring is required.

Durch die erfindungsgemäße Ausgestaltung dieses flüssigkeitsgekühlten Hochlastwiderstandes konnte die Induktivität gegenüber den bekannten Hochlastwiderständen erheblich verringert werden.The inventive design of this liquid-cooled high-load resistor made it possible to significantly reduce the inductance compared to the known high-load resistors.

Der benötigte platzbedarf für einen derartigen Hochlastwiderstand ist gering. Der Widerstandswert kann durch Veränderung der Länge, der Breite oder der Dicke des Leiterbandmaterials eingestellt werden. Für eine bestehende Konstruktion des Gehäuses ist die Variation der Leiterbanddicke zweckmäßig.The space requirement for such a high-load resistor is small. The resistance value can be adjusted by changing the length, the width or the thickness of the strip material. For an existing construction of the housing, the variation of the conductor strip thickness is appropriate.

Die abzuführende Verlustleistung wird mit der durchströmenden Flüssigkeitsmenge pro Zeiteinheit bestimmt. Beim erfindungsgemäßen Hochlastwiderstand besteht die Möglichkeit, die Leiterbandspirale einfach oder zweifach zu umströmen. Bei der erstgenannten Betriebsart fließt die Kühlflüssigkeit vom Zulauf ins Zentrum des Hochlastwiderstandes - Wendepunkt der bifilar gewickelten Leiterbandspirale - und zurück zum Ablauf. Bei der zweitgenannten Betriebsart sind ein weiterer Zu- und Ablauf im Wendebereich der bifilar gewickelten Leiterbandspirale angeordnet. Dadurch entstehen zwei parallele Kühlkanäle, die gleichsinnig oder gegensinnig mit Kühlflüssigkeit durchströmt werden können. Bei dieser Betriebsart kann pro zeiteinheit die doppelte Kühlflüssigkeitsmenge durch diesen Hochlastwiderstand strömen, wodurch sich auch die Verlustleistung, die an die Kühlflüssigkeit abgegeben wird, verdoppelt, ohne dabei den Platzbedarf des Hochlastwiderstandes zu verändern.The power loss to be dissipated is determined with the amount of liquid flowing through per unit of time. In the high-load resistor according to the invention Possibility to flow around the conductor tape spiral once or twice. In the first operating mode, the coolant flows from the inlet to the center of the high-load resistor - the turning point of the bifilar wound conductor strip spiral - and back to the outlet. In the second-mentioned operating mode, a further inlet and outlet are arranged in the turning area of the bifilar wound conductor strip spiral. This creates two parallel cooling channels that can be flowed through in the same direction or in opposite directions with cooling liquid. In this operating mode, twice the amount of coolant can flow through this high-load resistor per unit of time, which also doubles the power dissipated to the coolant without changing the space requirement of the high-load resistor.

Weitere vorteilhafte Ausführungsformen sind den Unteransprüchen 6 bis 9 zu entnehmen.Further advantageous embodiments can be found in subclaims 6 to 9.

Zur weiteren Erläuterung der Erfindung wird auf die Zeichnung Bezug genommen, in der ein Ausführungsbeispiel des erfindungsgemäßen flüssigkeitsgekühlten Hochlastwiderstandes schematisch veranschaulicht ist.

Figur 1
zeigt eine Draufsicht des erfindungsgemäßen Hochlastwiderstandes,
Figur 2
veranschaulicht eine Schnittdarstellung II-II nach Figur 1, in
Figur 3
ist das Widerstandselement näher dargestellt,
Figur 4
zeigt eine Ausführungsform des elektrischen Anschlusses des Widerstandselementes des Hochlastwiderstandes,in
Figur 5
ist eine weitere Schnittdarstellung III-III nach Figur 1 dargestellt und
Figur 6
zeigt eine weitere Schnittdarstellung IV-IV nach Figur 1.
To further explain the invention, reference is made to the drawing, in which an embodiment of the liquid-cooled high-load resistor according to the invention is schematically illustrated.
Figure 1
shows a plan view of the high-load resistor according to the invention,
Figure 2
illustrates a sectional view II-II of Figure 1, in
Figure 3
the resistance element is shown in more detail,
Figure 4
shows an embodiment of the electrical connection of the resistance element of the high-load resistor, in
Figure 5
is a further sectional view III-III shown in Figure 1 and
Figure 6
shows a further sectional view IV-IV of Figure 1.

In Figur 1 ist eine Draufsicht des erfindungsgemäßen flüssigkeitsgekühlten Hochlastwiderstandes dargestellt. Dieser Hochlastwiderstand besteht aus einem Gehäuse 2 und einem Widerstandselement 4, das in Figur 3 näher dargestellt ist. Zum besseren Verständnis wird gleichzeitig die zugehörige Schnittdarstellung II-II, dargestellt in Figur 2, mitbeschrieben. Das Gehäuse 2 des Hochlastwiderstandes besteht aus einer Kammer 6, in der das Widerstandselement 4 angeordnet ist, und einem Deckel 8. Als Deckel 8 ist eine Isolierplatte vorgesehen, die lösbar mit der Kammer 6 mittels eines umlaufenden Dichtringes 10 flüssigkeitsdicht verschlossen ist. Der Deckel 8 kann auch nicht lösbar mit der Kammer 6 verbunden werden. Die Kammer 6 besteht aus einer Isolierplatte 12 und einem Isolierring 14. Die Ecken des Isolierrings 14 sind als Flansche bzw. Befestigungsfahnen 16 ausgebildet. Die Isolierplatte 12, die den Boden der Kammer 6 bildet, ist ebenfalls mittels eines umlaufenden Dichtrings flüssigkeitsdicht verschlossen. In einer bevorzugten Ausführungsform des Hochlastwiderstandes bildet der Isolierring 14 und die Isolierplatte 12 eine Baueinheit.FIG. 1 shows a top view of the liquid-cooled high-load resistor according to the invention. This high-load resistor consists of a housing 2 and a resistance element 4, which is shown in more detail in Figure 3. For better understanding, the associated sectional view II-II, shown in Figure 2, is also described. The housing 2 of the high-load resistor consists of a chamber 6, in which the resistance element 4 is arranged, and a cover 8. As the cover 8, an insulating plate is provided which is detachably closed with the chamber 6 by means of a circumferential sealing ring 10 in a liquid-tight manner. The cover 8 can also not be detachably connected to the chamber 6. The chamber 6 consists of an insulating plate 12 and an insulating ring 14. The corners of the insulating ring 14 are designed as flanges or fastening tabs 16. The insulating plate 12, which forms the bottom of the chamber 6, is likewise closed in a liquid-tight manner by means of a circumferential sealing ring. In a preferred embodiment of the high-load resistor, the insulating ring 14 and the insulating plate 12 form a structural unit.

Zur mechanischen Fixierung des Widerstandselementes 4 auf der Isolierplatte 12 sind Noppen 18 aus elektrisch nicht leitendem Material vorgesehen. Diese Noppen 18 sind jeweils abwechselnd beidseitig entlang gedachter radialer Linien auf der Isolierplatte 12 gesteckt. Im Inneren des Widerstandselementes 4 sind Umlenkzapfen 20 und 22 angeordnet, die in der Figur 6 nächer dargestellt sind. Im Randbereich der Kammer 6 sind die elektrischen Anschlüsse 24 und 26 des Widerstandselementes 4 angeordnet. Ebenfalls im Randbereich der Kammer 6 sind in der Isolierplatte 8 ein Zulauf 28 und ein Ablauf 30 für das Kühlmittel angeordnet.Knobs 18 made of electrically non-conductive material are provided for mechanically fixing the resistance element 4 on the insulating plate 12. These knobs 18 are alternately inserted on both sides along imaginary radial lines on the insulating plate 12. Deflection pins 20 and 22 are arranged in the interior of the resistance element 4, which are shown in FIG. 6 below. The electrical connections 24 and 26 of the resistance element 4 are arranged in the edge region of the chamber 6. Also in the edge region of the chamber 6, an inlet 28 and an outlet 30 for the coolant are arranged in the insulating plate 8.

Wie in der Figur 2 dargestellt ist, wird das Widerstandselement 4 mittels der Isolierplatte 8 und der lösbaren Befestigungselemente derart in der Kammer 6 verspannt, daß die Kühlflüssigkeit durch einen rechteckförmigen Kanal 32 strömt.As shown in FIG. 2, the resistance element 4 is clamped in the chamber 6 by means of the insulating plate 8 and the releasable fastening elements in such a way that the cooling liquid flows through a rectangular channel 32.

In der Figur 3 ist das Widerstandselement 4 näher dargestellt. Als Widerstandselement 4 ist eine bifilar gewickelte Leiterbandspirale 34 vorgesehen, die an ihren freien Enden jeweils mit einem elektrischen Anschluß 24 und 26 versehen ist. Als Widerstandsmaterial kann beispielsweise ein Edelstahlband mit folgenden Maßen 0,5x10x4.000 mm³ vorgesehen sein. In den Mittelpunkten 36 und 38 dieser bifilar gewickelten Leiterbandspirale 34 sind exzentrisch zum Mittelpunkt 40 der Kammer 6 des Hochlastwiderstandes die Umlenkzapfen 20 und 22 angeordnet. Der Abstand des Mittelpunktes 36 zum Mittelpunkt 40 ist mit a und der Abstand des Mittelpunktes 38 zum Mittelpunkt 36 ist mit b gekennzeichnet. Mittels dieser Abstände können die Biegeradien des Leiterbandes des Widerstandselementes 4 bestimmt werden.The resistance element 4 is shown in more detail in FIG. As a resistance element 4, a bifilar wound conductor strip spiral 34 is provided, which is provided with an electrical connection 24 and 26 at its free ends. For example, a stainless steel band with the following dimensions 0.5x10x4,000 mm³ can be provided as the resistance material. In the center points 36 and 38 of this bifilar wound conductor strip spiral 34, the deflection pins 20 and 22 are arranged eccentrically to the center point 40 of the chamber 6 of the high-load resistor. The distance from the center 36 to the center 40 is marked with a and the distance from the center 38 to the center 36 is marked with b. The bending radii of the conductor strip of the resistance element 4 can be determined by means of these distances.

Im Mittelpunkt 36 kann zusätzlich zum Umlenkzapfen 20 ein weiterer Zulauf bzw. ein weiterer Ablauf und im Mittelpunkt 38 kann zusätzlich zum Umlenkzapfen 22 ein weiterer Ablauf bzw. ein weiterer Zulauf angeordnet sein. Durch die bifilar gewickelte Leiterbandspirale 34 und durch die mittig angeordneten Umlenkzapfen 20 und 22 erhält man einen spiralförmigen Kanal 32, durch den die Kühlflüssigkeit immer entgegengesetzt bezogen auf eine Trennwand (Leiterband) strömt. Diese beiden Strömungsrichtungen sind mittels unterbrochener Pfeile gekennzeichnet. Durch den weiteren Zulauf und den weiteren Ablauf wird die einkanalige Ausgestaltung des flüssigkeitsgekühlten Hochlastwiderstandes in eine zweikanalige Ausführungsform umgewandelt. Durch die Plazierung des Zulaufs 28, des Ablaufs 30, des weiteren Zulaufs und des weiteren Ablaufs kann das Kühlmittel in den beiden Kanälen in derselben Richtung oder entgegengesetzt fließen. Durch den zweiten Kanal kann die Durchflußmenge der Kühlflüssigkeit verdoppelt werden, wodurch auch die abzuführende Verlustleistung sich verdoppelt.In the center 36, in addition to the deflecting pin 20, a further inlet or a further outlet and in the center 38 can be arranged in addition to the deflecting pin 22, a further outlet or a further inlet. Through the bifilar wound conductor strip spiral 34 and through the centrally arranged deflection pins 20 and 22, a spiral channel 32 is obtained, through which the coolant always flows in the opposite direction relative to a partition (conductor strip). These two flow directions are indicated by broken arrows. As a result of the further inflow and outflow, the single-channel design of the liquid-cooled high-load resistor is converted into a two-channel embodiment. By placing the Inlet 28, outlet 30, the further inlet and the further outlet, the coolant can flow in the two channels in the same direction or in the opposite direction. The flow rate of the cooling liquid can be doubled through the second channel, as a result of which the power loss to be dissipated also doubles.

Da an den elektrischen Anschlüssen 24 und 26 der Leiterstrom zugeführt und abgeführt wird, werden die einzelnen Spiralgänge entgegengesetzt vom Strom durchflossen, wodurch die resultierende Induktivität dieses Widerstandselementes 4 minimal ist. Dazu trägt auch bei, daß das Widerstandsmaterial die Form eines Flachbandes hat (Figur 4), welches aufgrund der Geometrie im Vergleich zu einem Rundleiter eine niedrigere Eigeninduktivität aufweist.Since the conductor current is supplied and discharged at the electrical connections 24 and 26, the individual spiral paths are flowed through in the opposite direction by the current, as a result of which the resulting inductance of this resistance element 4 is minimal. This is also due to the fact that the resistance material has the form of a flat strip (FIG. 4), which, due to the geometry, has a lower self-inductance than a round conductor.

Der elektrische Anschluß 24 bzw. 26, von denen in der Figur 4 nur der Anschluß 26 dargestellt ist, besteht aus einem Steg 42, der auf einer Scheibe 44 angeordnet ist. Auf der dem Steg 42 abgewandten Seite der Scheibe 44 ist ein Gewindebolzen 46 angebracht. Die Leiterbandspirale 34 ist mit ihrem freien Ende mit dem Steg 42 elektrisch leitend verbunden. Eine Stirnseite 48 des Steges 42 schließt im eingebauten Zustand mit den Isolierring 14 (Kammerwand) ab und eine zum Eingang des Kühlkanals 32 gerichtete Stegseite 50 ist abgeschrägt, damit die Kühlflüssigkeit möglichst verwirbelungsfrei ein- und austreten kann.The electrical connection 24 or 26, of which only the connection 26 is shown in FIG. 4, consists of a web 42 which is arranged on a disk 44. A threaded bolt 46 is attached to the side of the disk 44 facing away from the web 42. The free end of the conductor strip spiral 34 is electrically conductively connected to the web 42. In the installed state, an end face 48 of the web 42 terminates with the insulating ring 14 (chamber wall) and a web side 50 directed towards the inlet of the cooling channel 32 is chamfered so that the cooling liquid can enter and exit as swirl-free as possible.

In Figur 5 ist eine weitere Schnittdarstellung III-III nach Figur 1 näher dargestellt. Diese Schnittdarstellung III-III zeigt einer seits einen elektrischen Anschluß 24 und andererseits den in der Isolierplatte 8 angeordneten Zulauf 28. Der elektrische Anschluß 24 besteht aus den bereits beschriebenen Teilen Steg 42, Scheibe 44 und Gewindebolzen 46 (Figur 4) und einem Anschlußleiter 52, der mittels einer Mutter 54 und einer Unterlegscheibe 56 mit dem Gewindebolzen 46 elektrisch leitend verbunden ist. Der Zulauf 28 besteht aus einem Stutzen 58, der mittels einer Dichtung 60 flüssigkeitsdicht in der Isolierplatte 8 verankert ist. Auf dem Stutzen 58 ist ein Kühlmittelschlauch 62 eines nicht näher dargestellten Kühlsystems gesteckt. In der dargestellten Schnittdarstellung III-III strömt die Kühlflüssigkeit durch den Schlauch 62 und den Stutzen 58 in den Eingang des Kühlkanals 32, dessen Öffnung in der Schnittebene liegt. D.h. die Kühlflüssigkeit tritt aus der Zeichenebene senkrecht heraus.FIG. 5 shows a further sectional illustration III-III according to FIG. 1. This sectional view III-III shows on the one hand an electrical connection 24 and on the other hand the inlet 28 arranged in the insulating plate 8. The electrical connection 24 consists of the parts of web 42, washer 44 and threaded bolt 46 (FIG. 4) and a connecting conductor 52, which is electrically conductively connected to the threaded bolt 46 by means of a nut 54 and a washer 56. The inlet 28 consists of a connection piece 58, which is anchored in the insulating plate 8 in a liquid-tight manner by means of a seal 60. A coolant hose 62 of a cooling system (not shown in any more detail) is plugged onto the connector 58. In the illustrated sectional illustration III-III, the cooling liquid flows through the hose 62 and the nozzle 58 into the entrance of the cooling channel 32, the opening of which lies in the sectional plane. That is, the coolant emerges vertically from the drawing plane.

In der Figur 6 ist eine weitere Schnittdarstellung IV-IV nach Figur 1 näher dargestellt. Diese Darstellung zeigt die Umlenkzapfen 20 und 22 in der Mitte der Kammer 6 des Hochlastwiderstandes. Diese Umlenkzapfen 20 und 22 dienen jeweils ebenfalls als Aufnahme für ein lösbares Befestigungsmittel 64, mit denen auch im Zentrum des Hochlastwiderstandes die bifilar gewickelte Leiterbandspirale 34 in der Kammer 6 gepreßt wird.FIG. 6 shows a further sectional view IV-IV according to FIG. 1. This illustration shows the deflecting pins 20 and 22 in the middle of the chamber 6 of the high-load resistor. These deflecting pins 20 and 22 each also serve as receptacles for a releasable fastening means 64, with which the bifilar wound conductor strip spiral 34 is also pressed in the chamber 6 in the center of the high-load resistance.

Durch die erfindungsgemäße Ausgestaltung dieses flüssigkeitsgekühlten Hochlastwiderstands weist dieser Widerstand einen Widerstandswert von nur 0,8Ω mit einer Belastbarkeit von 5 kW bei einer Durchflußmenge von 3 l/min bei der einkanaligen Ausführung. Die zweikanalige Ausführungsform weist eine Belastbarkeit von 10 kW bei einer Durchflußmenge von 6 l/min auf.Due to the inventive design of this liquid-cooled high-load resistor, this resistor has a resistance value of only 0.8Ω with a load capacity of 5 kW at a flow rate of 3 l / min in the single-channel version. The two-channel embodiment has a load capacity of 10 kW with a flow rate of 6 l / min.

Claims (9)

  1. Liquid-cooled heavy-duty resistor consisting of a housing (2) and a resistor element (4), the resistor element (4) being arranged inside a chamber (6) through which a cooling liquid flows from an inlet to the outlet (28, 30), characterized in that the chamber (6) consists of two insulating plates (8, 12) and an insulating ring (14) and in that, as resistor element (4), a bifilar-wound spiral strip conductor (34) is provided which is clamped between the two insulating plates (8, 12) in such a manner that the cooling liquid flows through a rectangular duct (32).
  2. Liquid-cooled heavy-duty resistor according to Claim 1, characterized in that the conductor strip of the resistor element (4) is provided with an insulating layer.
  3. Liquid-cooled heavy-duty resistor according to Claim 1, characterized in that the conductor strip of the resistor element (4) is mechanically fixed in location on an insulating plate (12) by means of knobs (18).
  4. Liquid-cooled heavy-duty resistor according to Claim 1, characterized in that the conductor strip of the resistor element (4) is mechanically fixed in location on an insulating plate (12) by means of a bifilar groove in this insulating plate (12).
  5. Liquid-cooled heavy-duty resistor according to Claim 1, characterized in that an insulating plate (12) and the insulating ring (14) form one constructional unit.
  6. Liquid-cooled heavy-duty resistor according to Claim 1, characterized in that an inlet and outlet (28, 30) are arranged at the edge area of the chamber (6) of the heavy-duty resistor.
  7. Liquid-cooled heavy-duty resistor according to Claim 1, characterized in that deflection pins (20, 22) are arranged in the interior of the resistor element (4) and a further inlet and outlet are arranged in the area of the deflection pins (20, 22).
  8. Liquid-cooled heavy-duty resistor according to Claim 1, characterized in that the electrical terminals (24, 26) of the resistor element (4) are arranged at the edge area of the chamber (6) of the heavy-duty resistor.
  9. Liquid-cooled heavy-duty resistor according to Claims 6 and 8, characterized in that the inlet and outlet (28, 30) and the electrical terminals (24, 26) are arranged aligned with one another oppositely to one another.
EP92918785A 1991-09-19 1992-09-08 Liquid-cooled heavy-duty resistor Expired - Lifetime EP0604481B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE9111719U 1991-09-19
DE9111719U DE9111719U1 (en) 1991-09-19 1991-09-19
PCT/DE1992/000762 WO1993006605A1 (en) 1991-09-19 1992-09-08 Liquid-cooled heavy-duty resistor

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EP0604481A1 EP0604481A1 (en) 1994-07-06
EP0604481B1 true EP0604481B1 (en) 1995-08-16

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EP (1) EP0604481B1 (en)
AT (1) ATE126624T1 (en)
CA (1) CA2119366C (en)
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WO (1) WO1993006605A1 (en)

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DE9111719U1 (en) * 1991-09-19 1991-11-07 Siemens Ag, 8000 Muenchen, De
DE9203354U1 (en) * 1992-03-12 1992-04-30 Siemens Ag, 8000 Muenchen, De
DE9409441U1 (en) * 1994-06-10 1994-08-04 Siemens Ag Liquid-cooled high-load resistor
US6452477B1 (en) * 2000-09-06 2002-09-17 Marconi Medical Systems, Inc. High voltage low inductance circuit protection resistor
US20090148657A1 (en) * 2007-12-05 2009-06-11 Jan Ihle Injection Molded PTC-Ceramics
US20090146042A1 (en) * 2007-12-05 2009-06-11 Jan Ihle Mold comprising a ptc-ceramic
US9034210B2 (en) * 2007-12-05 2015-05-19 Epcos Ag Feedstock and method for preparing the feedstock
US20090145977A1 (en) * 2007-12-05 2009-06-11 Jan Ihle Injection molded nozzle and injector comprising the injection molded nozzle
US20090148802A1 (en) * 2007-12-05 2009-06-11 Jan Ihle Process for heating a fluid and an injection molded molding
EP2897137B1 (en) 2014-01-16 2020-04-29 Vishay MCB Industrie High-power compact electrical resistance
US9514864B2 (en) * 2014-02-24 2016-12-06 Sandia Corporation Solid-state resistor for pulsed power machines
DE102018133195B4 (en) * 2018-12-20 2021-04-08 Auto-Kabel Management Gmbh High current resistance as well as circuit arrangement
US11394264B2 (en) 2020-01-21 2022-07-19 Itt Manufacturing Enterprises Llc Motor assembly for driving a pump or rotary device with a low inductance resistor for a matrix converter
US11451156B2 (en) 2020-01-21 2022-09-20 Itt Manufacturing Enterprises Llc Overvoltage clamp for a matrix converter

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DE410792C (en) * 1925-03-05 Oerlikon Maschf Cooling device for electrically heated, corrugated metal bands
GB191124679A (en) * 1910-11-07 1912-10-31 William Le Roy Emmet Improvements in and relating to Water Cooled Resistances.
US2254838A (en) * 1938-09-08 1941-09-02 Rca Corp Resistor
US3156889A (en) * 1962-06-14 1964-11-10 Aerospace Corp Rheostat
US3858146A (en) * 1973-06-04 1974-12-31 B Simonsen Electrical discharge resistor
DE3133485A1 (en) * 1980-09-15 1982-05-06 Peter 2563 Ipsach Herren LIQUID-COOLED ELECTRICAL ASSEMBLY
DE3267531D1 (en) * 1981-05-21 1986-01-02 Bbc Brown Boveri & Cie Liquid-cooled power resistor and its application
DE3639239A1 (en) * 1986-11-17 1988-05-19 Siemens Ag Liquid-cooled resistor
DE9111719U1 (en) * 1991-09-19 1991-11-07 Siemens Ag, 8000 Muenchen, De
DE9203354U1 (en) * 1992-03-12 1992-04-30 Siemens Ag, 8000 Muenchen, De

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US5508677A (en) 1996-04-16
DE59203311D1 (en) 1995-09-21
ATE126624T1 (en) 1995-09-15
DE9111719U1 (en) 1991-11-07
WO1993006605A1 (en) 1993-04-01
CA2119366C (en) 1997-06-17
EP0604481A1 (en) 1994-07-06
CA2119366A1 (en) 1993-04-01

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