Special-shaped precision detection resistor and production equipment thereof

Abstract

The invention discloses a special-shaped precision detection resistor and production equipment thereof, and relates to the technical field of resistor production and manufacturing, the special-shaped precision detection resistor comprises an alloy red copper shell and two resistor cores arranged in the alloy red copper shell, and one side of the alloy red copper shell is provided with two leading-out ends; the lead-out end is electrically connected with the resistor core, the outer wall of the bottom of the alloy red copper shell and the outer wall of the top of the alloy red copper shell are respectively provided with a plurality of groups of heat dissipation grooves and heat dissipation assemblies which are distributed at equal intervals, and the heat dissipation mechanism is located in the alloy red copper shell and comprises two water cooling pipes. The special-shaped precision detection resistor and the production equipment thereof disclosed by the invention have the effects of improving the stability of the resistor core during use, enhancing the heat dissipation performance of the resistor core, ensuring the reliability and safety of a system, improving the working efficiency of a brake resistor, prolonging the service life of the brake resistor, controlling and reducing the thermoelectromotive force and avoiding the occurrence of a condition of overhigh parasitic inductance.

Description

Technical Field

[0001] The invention relates to the technical field of resistor production and manufacturing, and in particular to a special-shaped precision detection resistor and production equipment thereof. Background Art

[0002] In modern industry and the automotive industry, brake resistors (also called brake resistors) are an important part of variable frequency drive systems. Among them, alloy resistors are another common type of brake resistors, which have good weather resistance and vibration resistance, so they can be used in more demanding industrial control environments. Braking resistors are mainly used to absorb the regenerative energy generated by the motor during deceleration or stopping. The feedback energy of the motor will be converted into heat energy for consumption through the brake resistor to prevent overvoltage of the power grid and protect the inverter from damage. If this part of the electrical energy is not consumed and processed in time, the inverter will frequently report overvoltage and may even cause damage to the inverter. Therefore, when the motor is in the power generation state, the resistor is equivalent to a load. The faster this part of the electrical energy is consumed, the faster the motor stops.

[0003] However, conventional brake resistors usually use traditional welding technology and non-full metal structures. Although they can meet basic energy consumption requirements to a certain extent, they are often prone to excessive internal temperature of the resistor due to poor heat dissipation, which in turn leads to serious heating. This heating phenomenon not only affects the life and performance of the brake resistor, but may also cause problems such as thermal electromotive force and large inductance leading to delayed response.

[0004] For example, take a brake resistor for electric vehicles, which uses traditional welding technology and ceramic packaging. During emergency braking after long-term high-speed driving, the brake resistor consumes a lot of energy, and its internal temperature rises rapidly. Due to the heat dissipation bottleneck of the welding point and the thermal conductivity limitation of the ceramic packaging material, the internal temperature of the resistor quickly exceeds the design limit. This not only causes the resistance value to change, affecting the stability and accuracy of the brake system, but also generates a large thermal electromotive force and inductance, which slows down the response speed of the brake system and cannot meet the requirements of high-frequency current detection. Finally, this brake resistor has performance degradation and shortened life after repeated use, and needs to be replaced with a new resistor before it can continue to be used. Summary of the invention

[0005] The present invention discloses a special-shaped precision detection resistor and a production device thereof, aiming to solve the technical problems that the conventional brake resistors usually adopt the traditional welding technology and the non-full metal structure, although they can meet the basic energy consumption requirements to a certain extent, but they are often easy to cause the internal temperature of the resistor to be too high due to their poor heat dissipation, and then cause serious heating phenomenon. This heating phenomenon not only affects the life and performance of the brake resistor, but also may generate thermoelectromotive force, large inductance leading to response lag and other problems.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] A special-shaped precision detection resistor comprises an alloy copper shell and two resistor cores arranged inside the alloy copper shell, two lead-out terminals are arranged on one side of the alloy copper shell, the lead-out terminals are electrically connected to the resistor core, and the bottom outer wall and the top outer wall of the alloy copper shell are respectively provided with a plurality of groups of equidistantly distributed heat dissipation grooves and heat dissipation components, and also comprises: a heat dissipation mechanism: located inside the alloy copper shell, the heat dissipation mechanism comprises two water-cooling pipes, two mounting grooves are arranged inside the alloy copper shell, and a heat conduction plate and a plurality of mounting cylinders are respectively installed on the inner walls on both sides of the mounting groove, a water-cooling pipe is installed on the outer wall of one side of the heat conduction plate, and a plurality of equidistantly distributed limiting buckles are arranged on the outer wall of one side of the water-cooling pipe, the limiting buckle is fixedly connected to the heat conduction plate, a reset spring is arranged inside the mounting cylinder, one end of the reset spring is fixedly connected to a clamping rod, and one end of the clamping rod is fixedly connected to the outer wall of one side of the heat conduction plate; a protective positioning mechanism: between the resistor core and the alloy copper shell; a shunt mechanism: located between the protective positioning mechanism and the resistor core.

[0008] The adoption of the above technical scheme can improve the stability of the resistor core during use, enhance its heat dissipation performance, ensure the reliability and safety of the system, improve the working efficiency and service life of the brake resistor, control and reduce the thermal electromotive force, and avoid excessive parasitic inductance. Specifically, first, by using the three-piece beam welding material welding process, electron beam welding process, Kelvin-terminal structure design and laser precision resistance repair / printing integrated process, the problems of large thermal electromotive force, large parasitic inductance, and difficulty in ensuring resistance accuracy and stability caused by poor heat dissipation performance of the resistor core after heating are solved. Then, the alloy resistor will inevitably generate heat when used. Part of the heat is dissipated through the heat dissipation slots in the heat dissipation assembly, part of the heat is conducted by the heat dissipation plate, and part of the heat is conducted out through the shunt mechanism, and then through the water The coolant is introduced into the water inlet of the cold pipe, and the heat-conducting plates near both sides of the resistor core can be water-cooled, so that the heat can be transferred to the outside of the alloy copper shell, thereby increasing the service life of the alloy resistor. The resistor core is easily displaced by slight vibration when working. Therefore, by using the clamping rod to squeeze the reset spring and support and limit the reaction force of the reset spring, the possibility of the resistor core being damaged by displacement and the liquid flowing out due to squeezing and rupture can be reduced. At the same time, bellows or other pipes with telescopic elasticity can be set at the water inlet and outlet, so that the water-cooling pipe can be displaced with the vibration and squeezing without being ruptured by lateral force, thereby avoiding the rupture of the water-cooling pipe and the possible outflow of coolant that may cause the resistor core to be scrapped.

[0009] In a preferred embodiment, the heat dissipation assembly includes a heat dissipation connecting frame, which is a connecting frame composed of multiple "convex" structures. The interior of the heat dissipation connecting frame is a hollow structure, and the top outer wall of the heat dissipation connecting frame is provided with fourteen heat dissipation grooves. A heat dissipation channel is formed between the bottom inner wall of the heat dissipation connecting frame and the heat dissipation grooves, wherein seven of the heat dissipation grooves are internally fixed with heat dissipation plates, and the bottom inner walls of the other seven heat dissipation grooves are each provided with three heat dissipation ports distributed at equal distances.

[0010] In this solution, the heat inside the alloy copper shell is transferred to the heat dissipation connection frame through conduction, and then the heat is transferred to the air through the heat dissipation grooves, heat dissipation channels and heat dissipation plates, and part of the heat is released to the external environment through the heat dissipation port, thereby achieving the purpose of heat dissipation.

[0011] In a preferred embodiment, the protective positioning mechanism includes two positioning insulating plates, two knobs and two groups of limit assemblies, the two positioning insulating plates are both located inside the alloy copper shell, one side outer wall of the two positioning insulating plates is provided with a positioning porcelain piece, the two lead-out ends pass through one of the positioning insulating plates and one of the positioning porcelain pieces in turn, and the lead-out ends are fixed to one side outer wall of the positioning insulating plate through the positioning porcelain piece, two mounting rods are provided on the outer wall of the positioning insulating plate away from the positioning porcelain piece, a first connecting rod, an adjusting rod and a second connecting rod are provided between the two mounting rods, the limit assembly includes two connecting plates, one of the connecting plates is connected to the circumferential outer wall of the adjusting rod by threads, the two connecting plates both pass through the first connecting rod and the second connecting rod, a mounting column and a fixing block are provided between the two connecting plates, the mounting column and the fixing block are provided with a support spring, and one end of the support spring is fixedly connected to the support plate.

[0012] In this solution, when in use, first turn the knob and then drive the adjusting rod to rotate, thereby realizing the movement of the two sets of limit assemblies on the first connecting rod and the second connecting rod, and then place the parts of the resistor core at both ends that are not wrapped with the resistance wire between the two support plates respectively, wherein the two support springs support the positions of the two ends of the resistor core close to the bottom outer wall, wherein the two support springs drive the support plates to limit the positions of the two ends of the resistor core close to the top outer wall. Compared with the traditional method of using only a single positioning porcelain part and a positioning insulating plate to limit the lead-out terminal and lead part of the resistor core to achieve the stability of the resistor core position, this device provides elasticity and buffering effect, which helps to maintain the stability of the lead-out terminal under vibration or impact conditions, ensures the stable positioning and protection of the lead-out terminal and the resistor core in the alloy copper shell, and reduces the risk of electrical failure and mechanical damage.

[0013] In a preferred embodiment, the shunt mechanism includes a plurality of shunt protrusions, which are respectively distributed on the inner walls on both sides, the top inner wall and the bottom inner wall of the alloy copper shell. A filling block is provided at the concave part of the shunt protrusion, and fillers are provided between the inner walls on the opposite side of the alloy copper shell and between the two positioning insulating plates. The shunt protrusion is a semi-arc structure, and the outer protrusion of the shunt protrusion is in the same direction as the position of the lead-out end.

[0014] In this scheme, fillers (silicates) are generally used to fill the gap between the inside of the alloy copper shell and the resistor core, which can form a continuous heat insulation layer, reduce the temperature of the outer surface of the resistor core, and thus slow down the heat dissipation rate. However, "slowing down the heat dissipation rate" here does not mean that it hinders the heat dissipation, but means making the heat dissipation process more efficient and stable by reducing heat loss. In fact, the heat insulation effect of silicate filling helps to better retain the heat generated by the resistor core inside and dissipate it through the alloy copper shell instead of directly dissipating it into the air. In order to prevent uneven distribution of silicates when filling silicates, multiple shunt bumps are set to guide the filling of silicates inside the alloy copper shell to make it more evenly distributed. The set filling blocks are connected by connecting ropes (attached Figure 6 The filling blocks are connected by connecting ropes (not marked in the figure, but there are illustrations of connecting ropes in the figure). When the silicate is filled along the shunt bump, the filling block will swing left and right and hit the inner wall of the alloy copper shell, generating a certain degree of vibration, thereby ensuring a more uniform distribution of silicate and the continuity and stability of the thermal insulation layer, thereby achieving efficient and stable heat dissipation of the resistor core.

[0015] As can be seen from the above, a special-shaped precision detection resistor includes an alloy copper shell and two resistor cores arranged inside the alloy copper shell, one side of the alloy copper shell is provided with two lead-out terminals, the lead-out terminals are electrically connected to the resistor core, the bottom outer wall and the top outer wall of the alloy copper shell are respectively provided with a plurality of groups of heat dissipation grooves and heat dissipation components distributed at equal distances, and also includes: a heat dissipation mechanism: located inside the alloy copper shell, the heat dissipation mechanism includes two water cooling pipes, the alloy copper shell is provided with two installation grooves inside, the installation grooves are provided with a plurality of groups of heat dissipation grooves and heat dissipation components distributed at equal distances, and ..., the installation grooves are provided with a plurality of groups of heat dissipation grooves and heat dissipation components distributed at equal distances, the heat dissipation mechanism includes two water cooling pipes, the alloy copper shell is provided with two installation grooves, the installation grooves are provided with a plurality of groups of heat dissipation grooves and heat dissipation components distributed at equal distances, the heat dissipation mechanism includes two water cooling pipes, the alloy copper shell is provided with two installation grooves, the installation grooves are provided The inner walls on both sides of the groove are respectively installed with heat conducting plates and several installation tubes, a water cooling tube is installed on the outer wall of one side of the heat conducting plate, and several equally spaced limit buckles are arranged on the outer wall of one side of the water cooling tube, and the limit buckles are fixedly connected to the heat conducting plate, and a reset spring is arranged inside the installation tube, and one end of the reset spring is fixedly connected to a clamping rod, and one end of the clamping rod is fixedly connected to the outer wall of one side of the heat conducting plate; the protective positioning mechanism: between the resistor core and the alloy copper shell; the shunt mechanism: located between the protective positioning mechanism and the resistor core. The special-shaped precision detection resistor and its production equipment provided by the present invention have the technical effects of improving the stability of the resistor core during use, enhancing its heat dissipation performance, ensuring the reliability and safety of the system, improving the working efficiency and service life of the brake resistor, controlling and reducing the thermoelectric potential, and avoiding the occurrence of excessive parasitic inductance. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a schematic diagram of the overall structure of a special-shaped precision detection resistor proposed by the present invention.

[0017] Figure 2 This is a front plan cross-sectional view of a special-shaped precision detection resistor proposed by the present invention.

[0018] Figure 3 for Figure 2 A schematic diagram of the enlarged structure in the middle.

[0019] Figure 4 The present invention provides a schematic diagram of the water cooling tube structure of a special-shaped precision detection resistor.

[0020] Figure 5 The present invention is a schematic diagram of the heat dissipation mechanism of a special-shaped precision detection resistor.

[0021] Figure 6 This is a schematic diagram of the structure of a current guiding mechanism of a special-shaped precision detection resistor proposed by the present invention.

[0022] Figure 7 The present invention is a schematic diagram of the protective positioning mechanism structure of a special-shaped precision detection resistor.

[0023] Figure 8This is a schematic diagram of the structure of a limit component of a special-shaped precision detection resistor proposed by the present invention.

[0024] Fig. 9 The present invention provides a schematic diagram of the overall structure of a special-shaped precision detection resistor production device.

[0025] Fig.10 The present invention provides a schematic diagram of a sleeve rod structure of a special-shaped precision detection resistor production device.

[0026] Fig.11 A plan cross-sectional view of a fixed component of a special-shaped precision detection resistor production device proposed by the present invention.

[0027] Fig.12 This is a schematic diagram of the structure of a mobile component of a special-shaped precision detection resistor production device proposed by the present invention.

[0028] Fig.13 This is a side view of the first mounting frame structure of a special-shaped precision detection resistor production equipment proposed by the present invention.

[0029] In the figure: 1. Alloy copper shell; 2. Lead-out terminal; 3. Heat dissipation groove; 4. Heat dissipation plate; 5. Heat dissipation groove; 6. Mounting groove; 7. Heat dissipation port; 8. Water cooling pipe; 9. Heat conduction plate; 10. Diverter bump; 11. Filling block; 12. Mounting rod; 13. Fixing block; 14. Support spring; 16. Water inlet; 17. Water outlet; 18. Limit buckle; 19. Mounting cylinder; 20. Reset spring; 21. Clamping rod; 22. Positioning porcelain piece; 23. Resistance wire; 24. Positioning insulation plate; 25. Support plate; 26. Knob; 27. Connecting plate; 29. ​​First Connecting rod; 30, adjusting rod; 31, second connecting rod; 33, first mounting bracket; 34, second mounting bracket; 35, first motor; 36, second motor; 37, first screw; 38, second screw; 39, ceramic skeleton; 40, limit frame; 41, sleeve; 42, positioning box; 43, limit column; 44, sleeve; 45, resistance alloy wire coil; 46, fixing bracket; 47, connecting spring; 48, limit ring; 49, pressure plate; 50, notch; 51, limit groove; 52, moving block; 53, connecting block; 54, limit opening; 55, belt. DETAILED DESCRIPTION

[0030] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0031] The present invention discloses a special-shaped precision detection resistor and its production equipment, which are mainly used in previous brake resistors, which usually adopt traditional welding technology and non-all-metal structure. Although they can meet the basic energy consumption requirements to a certain extent, they are often prone to excessive internal temperature of the resistor due to poor heat dissipation, thereby causing serious heating. This heating phenomenon not only affects the life and performance of the brake resistor, but may also cause thermoelectromotive force, large inductance leading to response lag and other problems.

[0032] Reference Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 A special-shaped precision detection resistor includes an alloy copper shell 1 and two resistor cores arranged inside the alloy copper shell 1. Two lead terminals 2 are arranged on one side of the alloy copper shell 1. The lead terminals 2 are electrically connected to the resistor core. The bottom outer wall and the top outer wall of the alloy copper shell 1 are respectively provided with a plurality of groups of heat dissipation grooves 5 and heat dissipation components distributed at equal distances. The heat dissipation mechanism also includes: a heat dissipation mechanism: located inside the alloy copper shell 1, the heat dissipation mechanism includes two water cooling pipes 8, and two installation grooves 6 are arranged inside the alloy copper shell 1. Both sides of the installation groove 6 A heat conducting plate 9 and several mounting tubes 19 are respectively installed on the inner wall, a water cooling tube 8 is installed on the outer wall of one side of the heat conducting plate 9, and several equally distributed limit buckles 18 are provided on the outer wall of one side of the water cooling tube 8, the limit buckles 18 are fixedly connected to the heat conducting plate 9, a reset spring 20 is provided inside the mounting tube 19, one end of the reset spring 20 is fixedly connected to a clamping rod 21, and one end of the clamping rod 21 is fixedly connected to the outer wall of one side of the heat conducting plate 9; protective positioning mechanism: between the resistor core and the alloy copper shell 1; shunt mechanism: located between the protective positioning mechanism and the resistor core.

[0033] Specifically, the middle part of the alloy copper shell 1 is alloy, and the two sides are copper.

[0034] Among them, the water cooling pipe 8 includes a water inlet 16 and a water outlet 17. The two ends of the water cooling pipe 8 respectively penetrate the outer walls of the alloy copper shell 1 on both sides. The water cooling pipe 8 is an "S"-shaped structure. The curved pipe increases the contact area between the cooling liquid and the alloy copper shell 1, thereby improving the heat exchange efficiency. By changing the direction of the pipe, the flow rate of the cooling liquid can be slowed down, the pressure in the pipe can be reduced, and the risk of leakage can be reduced. In a limited space, the space can be used more effectively by bending the pipe while maintaining the heat exchange efficiency.

[0035] In the specific implementation process, the heat dissipation component includes a heat dissipation connection frame, which is a connection frame composed of multiple "convex" structures. The interior of the heat dissipation connection frame is a hollow structure, and fourteen heat dissipation grooves 3 are opened on the top outer wall of the heat dissipation connection frame. A heat dissipation channel is formed between the bottom inner wall of the heat dissipation connection frame and the heat dissipation groove 3, wherein seven heat dissipation grooves 3 are fixedly plugged into the heat dissipation plates 4, and the bottom inner walls of the other seven heat dissipation grooves 3 are each provided with three heat dissipation ports 7 distributed at equal distances. The heat inside the alloy copper shell 1 is transferred to the heat dissipation connection frame through conduction, and then the heat is transferred to the air through the heat dissipation grooves 3, the heat dissipation channel and the heat dissipation plate 4, and part of the heat is released to the external environment through the heat dissipation ports 7, thereby achieving the purpose of heat dissipation.

[0036] Among them, the series of problems caused by the heating of the brake resistor mentioned in the background technology are specifically manifested as follows: when the current generated by the motor or brake is too large, the brake resistor will generate heat, which may easily cause the resistor temperature to be too high, and then cause serious heating, which will not only affect the life and performance of the brake resistor, but also may generate thermal electromotive force, which will interfere with surrounding electronic equipment. Thermoelectric force is in the brake resistor. Due to the passage of current, heat is generated. If the heat dissipation is poor, a temperature gradient will be formed inside the resistor, which may interfere with surrounding electronic equipment and affect the accuracy of current detection;

[0037] The so-called excessive inductance refers to the parasitic inductance being too high, which will have a negative impact on the dynamic response of the circuit. Excessive parasitic inductance will increase the inertia of the circuit, making the circuit respond slower to changes in the input signal, that is, the dynamic response is slow. For example: in the circuit where the brake resistor is located, if the parasitic inductance is too high, it may cause the circuit to become slow in responding to the brake signal. This may affect the braking effect of the motor and even cause braking failure;

[0038] In addition, the brake resistor generates heat during operation, which will directly cause its internal temperature to rise. The temperature change will also affect the resistivity of the resistor material, thereby causing the resistance value to change. This change may manifest as difficulty in ensuring the resistance accuracy and stability, especially serious drift after long-term operation.

[0039] It should be noted that, in response to the above specific problems, in addition to the innovative heat dissipation structure design of the alloy resistor brake resistor, it also relies on advanced manufacturing technology: 1. The product is produced using all-metal three-piece beam welding materials, which have excellent thermal conductivity and high temperature resistance. After special welding process treatment and surface pickling and passivation treatment, it not only enhances the corrosion resistance of the material surface, but also improves its wear resistance under extreme working conditions. The resulting resistor element can maintain excellent performance stability and reliability in a wide temperature range of -55°C to +170°C, and is suitable for a variety of harsh environment application scenarios. While meeting the requirements of green manufacturing, it has successfully achieved breakthroughs in multiple key performance aspects of the product: such as significantly reducing the inductance effect during welding to achieve an ultra-low inductance level, controlling and reducing the welding thermoelectric potential, enhancing the thermal stability of the product, and maintaining excellent stability over a wide temperature range, allowing the product to operate stably and reliably in various complex environments.

[0040] 2. Electron beam welding technology is used in the resistor manufacturing process. No additional welding materials are needed during the operation. High-energy electron beams are used to bombard the joints between the resistor element and the copper electrode, instantly heating the welding area to the melting point and rapidly cooling and solidifying it, thereby forming a low-impedance connection between the resistor element and the copper electrode. This process effectively avoids the risk of base material composition variation and performance loss due to the intervention of foreign substances, while reducing thermal deformation and thermal stress damage, ensuring the metallurgical bonding quality of the welding interface, and giving the material excellent electrical conductivity and mechanical strength.

[0041] 3. The product adopts the Kelvin 4-terminal structure design, which aims to effectively reduce the influence of lead resistance on current detection accuracy. Through this structural design, not only the accuracy of current measurement is significantly improved, but also the thermal voltage effect of the resistor element is greatly optimized. The application of the double bridge method ensures that the actual resistance value of the measured resistor is measured, rather than the additional lead resistance, thereby greatly reducing the error caused by the lead resistance, ensuring the high reliability of the current detection results, and improving the accuracy of the entire brake system. In addition, another important advantage of the Kelvin 4-terminal structure is that it can reduce the system's sensitivity to temperature changes. During operation, as the resistor heats up, the Kelvin connection allows the temperature monitoring circuit to be isolated from the main circuit, and precise measurements are made specifically for the target resistor, which can accurately reflect the temperature characteristics of the resistor itself without being affected by the contact resistance or lead resistance fluctuations with temperature. Therefore, even at an operating power of up to 10W, the design can ensure the stability of the resistor performance and the consistency of the data, ensuring high performance under long-term use.

[0042] 4. In terms of resistance control, the present invention adopts an integrated process of laser precision resistance trimming and printing. This process uses a high-precision laser beam to accurately irradiate the surface of the resistor material, and fine-tune the resistance value by changing the effective cross-sectional area of ​​the material, thereby achieving high-precision resistance control of up to ±0.5%, ±1% and ±5%. In addition, with the help of the same laser beam, laser printing and marking are immediately performed on the product surface after the resistance trimming operation is completed, which improves the clarity and durability of the product marking, simplifies the production process, enhances the overall consistency of the product, and thus reduces the probability of errors caused by manual operation, ensuring that the resistor elements meet high standards of precision requirements, simplifies the traditional cumbersome production process, improves production efficiency, and achieves efficient, precise and stable process integration, providing strong production guarantees for product quality.

[0043] During specific use, the heat sink 4 can be made of copper sheet, which can quickly transfer the heat generated by the resistor core to the alloy copper shell 1 by heat conduction. The shape, size and number of the heat sink 4 can be designed according to the power and heat dissipation requirements of the alloy resistor to achieve the best heat dissipation effect.

[0044] The specific principle of use is as follows: when the alloy resistor is in use, heat is bound to be generated. Part of the heat is dissipated through the heat dissipation slot 5 in the heat dissipation assembly, part of the heat is conducted by the heat dissipation plate 4, and part of the heat is conducted out through the shunt mechanism. Then, by introducing coolant into the water inlet 16 of the water-cooling pipe 8, the heat-conducting plates 9 close to both sides of the resistor core can be water-cooled, so that the heat can be conducted to the outside of the alloy copper shell 1, thereby increasing the service life of the alloy resistor. When the resistor core is working, it is easily displaced by slight vibration. Therefore, by using the clamping rod 21 to squeeze the reset spring 20 and supporting and limiting the reaction force of the reset spring 20, the possibility of damage to the resistor core due to displacement and the outflow of liquid due to squeezing and rupture can be reduced. At the same time, a bellows or other pipes with telescopic elasticity can be set at the water inlet 16 and the water outlet 17, so that the water-cooling pipe 8 can be displaced with the vibration squeezing without being ruptured by the lateral force, thereby avoiding the rupture of the water-cooling pipe 8 and the occurrence of the scrapping of the resistor core due to the outflow of coolant.

[0045] Reference Figure 6 , Figure 7 and Figure 8In a preferred embodiment, the protective positioning mechanism includes two positioning insulating plates 24, two knobs 26 and two groups of limiting components. The two positioning insulating plates 24 are both located inside the alloy copper shell 1. One side outer wall of the two positioning insulating plates 24 is provided with a positioning porcelain piece 22. The two lead-out terminals 2 pass through one of the positioning insulating plates 24 and one of the positioning porcelain pieces 22 in turn, and the lead-out terminals 2 are fixed to one side outer wall of the positioning insulating plate 24 through the positioning porcelain piece 22. Two mounting rods 12 are provided on the outer wall of the side of the positioning insulating plate 24 away from the positioning porcelain piece 22. A first connecting rod 29, an adjusting rod 30 and a second connecting rod 31 are provided between the two mounting rods 12. The limiting component includes two connecting plates 27, one of which is connected to the circumferential outer wall of the adjusting rod 30 by threads, and the two connecting plates 27 are both inserted into the first connecting rod 29 and the second connecting rod 31. A mounting column and a fixing block 13 are provided between the two connecting plates 27. A support spring 14 is provided on the mounting column and the fixing block 13, and one end of the support spring 14 is fixedly connected to a support plate 25.

[0046] It should be noted that the positioning insulating plate 24 is made of high-temperature resistant mica material with good insulation performance, and the entire protective positioning mechanism uses non-magnetic insulating material to avoid electromagnetic interference to the alloy resistor. For example, materials made of ceramics, glass fiber, etc. have excellent insulation performance and stability, and will not cause electromagnetic interference to the alloy resistor.

[0047] Among them, the adjustment rod 30 is a two-way threaded structure, one end of the adjustment rod 30 is fixedly connected to the knob 26, and the end of the adjustment rod 30 away from the knob 26 is connected to the outer wall of one side of the mounting rod 12 through a bearing. The support plate 25 is an arc structure, and two adjacent support plates 25 form an elliptical structure. It should be noted that the inside of the resistor core is a flat cylindrical structure. The elliptical structure design may be used to adapt to the external shape of the resistor core, and it can also allow the support plate 25 to undergo a slight deformation when subjected to external force to a certain extent, thereby absorbing and dispersing stress and protecting other components from damage. The two-way threaded rod facilitates the two limit assemblies to adjust the spacing between the two resistor cores according to the width of the two resistor cores.

[0048] In the specific implementation process, four of the support springs 14 are arranged to be inclined downward, and the other four support springs 14 are arranged to be inclined upward. The support springs 14 are stretched in one direction due to their own elastic force, thereby providing downward thrust or upward support force, which helps to maintain the stability of the support plate 25, the resistor core and the lead-out terminal 2 under vibration or impact conditions.

[0049] Specifically, when in use, first turn the knob 26, and then drive the adjusting rod 30 to rotate, so that the two sets of limit assemblies can be moved on the first connecting rod 29 and the second connecting rod 31, and then the parts of the resistor core that are not wrapped with the resistance wire 23 are placed between the two support plates 25 respectively, wherein the two support springs 14 support the two ends of the resistor core near the bottom outer wall position, wherein the two support springs 14 drive the support plates 25 to limit the two ends of the resistor core near the top outer wall position. Compared with the traditional method of using only a single positioning porcelain part 22 and a positioning insulating plate 24 to limit the lead-out terminal 2 and the lead part of the resistor core to achieve the stability of the resistor core position, the present device provides elasticity and buffering effect, which helps to maintain the stability of the lead-out terminal 2 under vibration or impact conditions, ensures the stable positioning and protection of the lead-out terminal 2 and the resistor core in the alloy copper housing 1, and reduces the risk of electrical failure and mechanical damage.

[0050] Reference Figure 6 In a preferred embodiment, the shunt mechanism includes a plurality of shunt protrusions 10, which are respectively distributed on the inner walls of both sides, the top inner wall and the bottom inner wall of the alloy copper shell 1. A filling block 11 is provided at the concave part of the shunt protrusion 10, and a filling material is provided between the inner walls of the opposite side of the alloy copper shell 1 and between the two positioning insulating plates 24. The shunt protrusion 10 is a semi-arc structure, and the outer protrusion of the shunt protrusion 10 is in the same direction as the position of the lead-out terminal 2.

[0051] It should be noted that the volume of the filling block 11 is larger than that of silicate, and the filling block 11 is a spherical structure. The filling block 11 can be made of alumina ceramic material, which has high pressure strength, high hardness, good corrosion resistance and low friction coefficient, as well as good thermal conductivity and insulation.

[0052] Specifically, silicate is generally used as a filler to fill the gap between the inside of the alloy copper shell 1 and the resistor core, which can form a continuous insulation layer, reduce the temperature of the outer surface of the resistor core, and thus slow down the heat dissipation rate. However, "slowing down the heat dissipation rate" here does not mean that it hinders the heat dissipation, but means making the heat dissipation process more efficient and stable by reducing heat loss. In fact, the thermal insulation effect of silicate filling helps to better retain the heat generated by the resistor core inside and dissipate it through the alloy copper shell 1 instead of directly dissipating it into the air. In order to prevent uneven distribution of silicate when filling silicate, a plurality of shunt protrusions 10 are set to guide the filling of silicate inside the alloy copper shell 1 to make it more evenly distributed. The set filling blocks 11 are connected by connecting ropes (attached Figure 6The filling blocks 11 are connected together (not shown in the figure, but there is an illustration of the connecting rope in the figure). When the silicate is filled along the shunt protrusion 10, the filling block 11 will swing left and right, and at the same time hit the inner wall of the alloy copper shell 1, generating a certain degree of vibration, thereby ensuring a more uniform distribution of the silicate and the continuity and stability of the heat insulation layer, thereby achieving efficient and stable heat dissipation of the resistor core.

[0053] Reference Fig. 9 , Fig.10 , Fig.11 , Fig.12 and Fig.13 A production device for special-shaped precision detection resistors includes two first mounting frames 33, the resistor core includes a ceramic frame 39 and a resistor wire 23, the resistor wire 23 is evenly wound on the outer wall of the ceramic frame 39, a second mounting frame 34 is provided on one side of the outer wall of one first mounting frame 33, a first motor 35 and a second motor 36 are provided on one side of the outer wall of the second mounting frame 34, a first screw rod 37, a second screw rod 38, two limit rods and two limit frames 40 are provided between the two first mounting frames 33, one end of the first screw rod 37 is fixedly connected to the output shaft of the first motor 35, the output shaft of the second motor 36 and one end of the second screw rod 38 are sleeved with a belt 55, the resistor core is located between the two first mounting frames 33, and the two ends of the ceramic frame 39 are respectively clamped on the two limit frames 4 0, the output shaft of the second motor 36 passes through the outer wall of one side of one of the first mounting frames 33, and the output shaft of the second motor 36 is fixedly connected to one of the limit frames 40, a sleeve rod 44 is connected to the inside of one of the first mounting frames 33, and one of the limit frames 40 is connected to one end of the sleeve rod 44 through a bearing, a sleeve 41 is provided on the outer wall of one side of one of the first mounting frames 33, a limit ring 48 is provided on the circumferential outer wall of the sleeve rod 44, a connecting spring 47 is provided on the inner wall of one side of the sleeve 41, one end of the connecting spring 47 is fixedly connected to the limit ring 48, the resistor core is located between the first screw rod 37 and the second screw rod 38, the circumferential outer wall of the first screw rod 37 is connected to a fixed component by a thread, and the circumferential outer wall of the second screw rod 38 is connected to a moving component by a thread.

[0054] The fixing assembly includes a positioning box 42 and a limiting column 43. A notch 50 is provided on the outer wall of one side of the positioning box 42. One end of the limiting column 43 is connected to the inside of the positioning box 42 by a thread. One end of the limiting column 43 is connected to a pressure plate 49 by a bearing. A limiting groove 51 is provided on the inner wall of the opposite side of the positioning box 42. Both outer walls of the pressure plate 49 are provided with moving blocks 52. The moving blocks 52 are slidably connected to the inner wall of the limiting groove 51. One end of the first screw rod 37 and one end of one of the limiting rods completely penetrate the outer wall of one side of the positioning box 42. When in use, one end of the resistance wire 23 is passed through the notch 50. Since the limiting column 43 is connected to the positioning box 42 by a thread, by rotating the limiting column 43 , which will drive the pressure plate 49 to move in the positioning box 42. When the pressure plate 49 moves to the appropriate position, it will directly contact and fix one end of the resistor core. At this time, since the moving block 52 is slidably connected to the inner wall of the limiting groove 51, the pressure plate 49 will remain stable during the movement and will not deviate from the predetermined trajectory due to external force, thereby realizing the up and down movement of the pressure plate 49 in the positioning box 42, and then being able to clamp and fix the resistor wire 23 according to the distance between the pressure plate 49 and the inner wall of the bottom of the notch 50, thereby ensuring its stability during the processing. When the resistor core is processed, the pressure plate 49 can be moved away from the resistor core by rotating the limiting column 43 in the opposite direction, so that it can be easily removed from the equipment.

[0055] In the specific use process, the moving assembly includes a connecting block 53, one end of the second screw rod 38 and one end of one of the limit rods completely penetrate the outer wall of one side of the connecting block 53, and a limit opening 54 is provided on the outer wall of one side of the connecting block 53. The outer walls of both sides of the connecting block 53 are provided with a fixing frame 46, and the resistance alloy wire coil 45 is connected between the two fixing frames 46 through a bearing. When the second motor 36 is started, the second screw rod 38 can be driven to rotate synchronously under the connection of the belt 55. Since one end of the second screw rod 38 penetrates the outer wall of one side of the connecting block 53, and one of the limit rods Under the action of, the connecting block 53 will move along the axial direction of the second screw rod 38. During the processing, the resistance alloy wire coil 45 is mainly used to provide additional resistance wire 23 material. The other end of the resistance wire 23 passes through the limit opening 54. When the ceramic skeleton 39 rotates in place driven by the output shaft of the second motor 36, the connecting block 53 moves synchronously on the second threaded rod. The resistance wire 23 can be accurately stretched, wound and positioned on the ceramic skeleton 39. This rotation also helps to evenly distribute and tightly fit the resistance wire 23 on the ceramic skeleton 39, ensuring the accuracy and stability of the resistance value.

[0056] Specifically, when in use, the resistor core consisting of a ceramic skeleton 39 and a uniformly wound resistor wire 23 is placed between two first mounting frames 33, ensuring that the two ends of the ceramic skeleton 39 of the resistor core are respectively clamped in the two limit frames 40 to maintain its stability during the processing. The first motor 35 is started, and its output shaft directly drives the first screw 37 to rotate. With the cooperation of one of the limit rods and the first screw 37, the fixing component is controlled to move on the first screw 37 according to the actual winding length requirement of the resistor core, and then one end of the resistor wire 23 on the resistor core is fixed to ensure that it will not move due to the force during the processing. The second motor 36 is started again, and its output shaft drives one of the limit frames 40 to rotate. At the same time, the output shaft of the second motor 36 and the second screw 38 are driven by the belt 55, so that the second screw 38 rotates synchronously. This design allows the resistor core to be driven to rotate in situ during the processing. The second screw 38 is threaded The connected moving component is used to move or adjust the other end of the resistance wire 23 when it is wrapped around the ceramic skeleton 39 during the processing. As the second screw 38 rotates, the moving component moves along the surface of the second screw 38 under the limiting action of one of the limiting rods, thereby driving the other end of the resistor core to make corresponding adjustments. Since one of the limiting frames 40 is connected to the first mounting frame 33 through the bearing block and the sleeve rod 44, when the sleeve rod 44 is pulled outward, the limiting ring 48 on the sleeve rod 44 will squeeze the connecting spring 47 in the sleeve 41, and then the limiting frame 40 will be smoothly clamped with one end of the ceramic skeleton 39, and then the outward pulling force will be released. At this time, under the elastic force of the connecting spring 47, the two limiting frames 40 clamp and limit the two ends of the ceramic skeleton 39. This design can adjust the distance between the two limiting frames 40 according to the actual length of the ceramic skeleton 39 during the processing, thereby maintaining the stability of clamping and limiting the two ends of the ceramic skeleton 39.

[0057] Working principle: When the alloy resistor is in use, heat is bound to be generated. Part of the heat is dissipated through the heat dissipation groove 5 in the heat dissipation component, part of the heat is conducted by the heat dissipation plate 4, and part of the heat is conducted out through the diversion mechanism. Then, the coolant is introduced into the water inlet 16 of the water-cooling pipe 8, and the heat-conducting plate 9 close to both sides of the resistor core can be water-cooled, so that the heat can be conducted to the outside of the alloy copper shell 1, thereby improving the service life of the alloy resistor. When the resistor core is working, it is easy to be displaced by slight vibration. Therefore, by using the clamping rod 21 to squeeze the reset spring 20 and supporting and limiting the reaction force of the reset spring 20, the possibility of damage to the resistor core due to displacement and the outflow of liquid due to squeezing and rupture can be reduced. At the same time, a bellows or other pipes with telescopic elasticity can be set at the water inlet 16 and the water outlet 17, so that the water-cooling pipe 8 can be displaced with the vibration and squeezing without being ruptured by the lateral force, thereby avoiding the rupture of the water-cooling pipe 8 and the occurrence of the scrapping of the resistor core due to the outflow of coolant.

[0058] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A special-shaped precision detection resistor, comprising an alloy copper shell (1) and two resistor cores arranged inside the alloy copper shell (1), characterized in that: Two lead-out terminals (2) are arranged on one side of the alloy copper shell (1), and the lead-out terminals (2) are electrically connected to the resistor core. The bottom outer wall and the top outer wall of the alloy copper shell (1) are respectively provided with a plurality of groups of heat dissipation grooves (5) and heat dissipation components that are distributed at equal distances, and further include: A heat dissipation mechanism: located inside the alloy copper shell (1), the heat dissipation mechanism comprises two water cooling tubes (8), two installation grooves (6) are provided inside the alloy copper shell (1), a heat conducting plate (9) and a plurality of installation tubes (19) are respectively installed on the inner walls on both sides of the installation groove (6), a water cooling tube (8) is installed on the outer wall of one side of the heat conducting plate (9), a plurality of equidistantly distributed limiting buckles (18) are provided on the outer wall of one side of the water cooling tube (8), the limiting buckles (18) are fixedly connected to the heat conducting plate (9), a return spring (20) is provided inside the installation tube (19), one end of the return spring (20) is fixedly connected to a clamping rod (21), and one end of the clamping rod (21) is fixedly connected to the outer wall of one side of the heat conducting plate (9); Protective positioning mechanism: between the resistor core and the alloy copper shell (1); Shunt mechanism: located between the protection positioning mechanism and the resistor core.

2. A special-shaped precision detection resistor according to claim 1, characterized in that: The water cooling pipe (8) comprises a water inlet (16) and a water outlet (17); the two ends of the water cooling pipe (8) respectively penetrate the outer walls of both sides of the alloy copper shell (1); and the water cooling pipe (8) is an "S"-shaped structure.

3. A special-shaped precision detection resistor according to claim 2, characterized in that: The heat dissipation component comprises a heat dissipation connection frame, which is a connection frame composed of multiple "convex" structures. The interior of the heat dissipation connection frame is a hollow structure, and the top outer wall of the heat dissipation connection frame is provided with fourteen heat dissipation grooves (3). A heat dissipation channel is formed between the bottom inner wall of the heat dissipation connection frame and the heat dissipation grooves (3), wherein seven of the heat dissipation grooves (3) are internally fixed with heat dissipation plates (4), and the bottom inner walls of the other seven heat dissipation grooves (3) are each provided with three heat dissipation ports (7) distributed at equal distances.

4. The special-shaped precision detection resistor according to claim 1, characterized in that: The protective positioning mechanism comprises two positioning insulating plates (24), two knobs (26) and two sets of limiter components. The two positioning insulating plates (24) are both located inside the alloy copper shell (1). One side outer wall of the two positioning insulating plates (24) is provided with a positioning porcelain piece (22). The two lead-out ends (2) pass through one of the positioning insulating plates (24) and one of the positioning porcelain pieces (22) in sequence, and the lead-out ends (2) are fixed to one side outer wall of the positioning insulating plates (24) through the positioning porcelain piece (22). Two mounting rods are provided on the side outer wall of the positioning insulating plates (24) away from the positioning porcelain piece (22). (12), a first connecting rod (29), an adjusting rod (30) and a second connecting rod (31) are provided between the two mounting rods (12), the limiting assembly comprises two connecting plates (27), one of the connecting plates (27) is connected to the circumferential outer wall of the adjusting rod (30) by a thread, the two connecting plates (27) both pass through the first connecting rod (29) and the second connecting rod (31), a mounting column and a fixing block (13) are provided between the two connecting plates (27), the mounting column and the fixing block (13) are both provided with a supporting spring (14), one end of the supporting spring (14) is fixedly connected to the supporting plate (25).

5. A special-shaped precision detection resistor according to claim 4, characterized in that: The adjusting rod (30) is a bidirectional threaded structure, one end of the adjusting rod (30) is fixedly connected to the knob (26), and the end of the adjusting rod (30) away from the knob (26) is connected to an outer wall of one side of the mounting rod (12) through a bearing, and the supporting plate (25) is an arc-shaped structure, and two adjacent supporting plates (25) form an elliptical structure.

6. A special-shaped precision detection resistor according to claim 5, characterized in that: Four of the support springs (14) are arranged obliquely downward, and the other four of the support springs (14) are arranged obliquely upward.

7. The special-shaped precision detection resistor according to claim 4, characterized in that: The shunt mechanism comprises a plurality of shunt protrusions (10), wherein the plurality of shunt protrusions (10) are respectively distributed on the inner walls on both sides, the top inner wall and the bottom inner wall of the alloy copper shell (1); a filling block (11) is provided at the inner concave part of the shunt protrusion (10); a filling material is provided between the inner walls on the opposite side of the alloy copper shell (1) and between the two positioning insulating plates (24); the shunt protrusion (10) is a semi-arc structure, and the outer protrusion of the shunt protrusion (10) is in the same direction as the position of the lead-out end (2).

8. A device for producing a special-shaped precision detection resistor as claimed in any one of claims 1 to 7, comprising two first mounting frames (33), characterized in that: The resistor core comprises a ceramic frame (39) and a resistance wire (23), wherein the resistance wire (23) is evenly wound around the outer wall of the ceramic frame (39), a second mounting frame (34) is provided on one side outer wall of one of the first mounting frames (33), a first motor (35) and a second motor (36) are provided on one side outer wall of the second mounting frame (34), a first screw rod (37), a second screw rod (38), two limit rods and two limit frames (40) are provided between the two first mounting frames (33), one end of the first screw rod (37) is fixedly connected to the output shaft of the first motor (35), the output shaft of the second motor (36) and one end of the second screw rod (38) are sleeved with a belt (55), the resistor core is located between the two first mounting frames (33), the two ends of the ceramic frame (39) are respectively clamped in the inside of the two limit frames (40), the second motor (36) The output shaft of the second motor (36) passes through an outer wall of one side of one of the first mounting frames (33), and the output shaft of the second motor (36) is fixedly connected to one of the limit frames (40). A sleeve rod (44) is connected to the interior of one of the first mounting frames (33), and one of the limit frames (40) is connected to one end of the sleeve rod (44) through a bearing. A sleeve (41) is provided on an outer wall of one side of one of the first mounting frames (33), and a limit ring (48) is provided on the circumferential outer wall of the sleeve rod (44). A connecting spring (47) is provided on an inner wall of one side of the sleeve (41), and one end of the connecting spring (47) is fixedly connected to the limit ring (48). The resistor core is located between the first screw rod (37) and the second screw rod (38). The circumferential outer wall of the first screw rod (37) is connected to a fixed component through a thread, and the circumferential outer wall of the second screw rod (38) is connected to a moving component through a thread.

9. The production equipment of a special-shaped precision detection resistor according to claim 8, characterized in that: The fixing assembly includes a positioning box (42) and a limiting column (43), a notch (50) is provided on an outer wall of one side of the positioning box (42), one end of the limiting column (43) is connected to the interior of the positioning box (42) by a thread, one end of the limiting column (43) is connected to a pressure plate (49) by a bearing, and limiting grooves (51) are provided on the inner walls of the opposite sides of the positioning box (42), and moving blocks (52) are provided on the outer walls of both sides of the pressure plate (49), and the moving blocks (52) are slidably connected to the inner walls of the limiting grooves (51), and one end of the first screw rod (37) and one end of one of the limiting rods completely penetrate the outer wall of one side of the positioning box (42).

10. The production equipment of special-shaped precision detection resistor according to claim 9, characterized in that: The moving assembly comprises a connecting block (53), one end of the second screw rod (38) and one end of one of the limiting rods completely penetrate an outer wall of one side of the connecting block (53), a limiting opening (54) is provided on an outer wall of one side of the connecting block (53), and both outer walls of the connecting block (53) are provided with fixing frames (46), and a resistance alloy wire coil (45) is connected between the two fixing frames (46) via a bearing.

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