Water cooled off-load resistor

Abstract

The utility model discloses a water -cooled no -load resistor, including shell and resistance collection, the shell is hollow closed casing structure, is equipped with water inlet and water outlet on the shell, resistance collection is equipped with the resistance monomer of multiple even adopt heat conduction type resistance structure, multiple resistance monomers all are with its both ends sealed and extend in the mode of the shell outside to be equipped in the shell, and multiple resistance monomers are connected in series and / or parallel, and lead out output terminal, the shell is spaced apart and is equipped with a plurality of fender in, to adjust the cooling water flow direction and flow in the shell, the shell is equipped with the shell cover of sealing cover and is equipped with the shell outside both ends of multiple resistance monomers, and pours and seals the insulating material layer between the shell cover and the shell, output terminal sealed and extends outside the shell cover. This water -cooled no -load resistor sets high voltage, high power, high resistance, high heat dissipation efficiency, good ground insulation withstand voltage performance, simple and reasonable structure, easy to process and make, and the advantages such as low manufacturing cost are integrated, and the market demand is satisfied very well.

Description

Technical Field

[0001] This utility model relates to the field of resistor technology, and in particular to a water-cooled unloaded resistor. Background Technology

[0002] An unloaded resistor is a resistor connected in parallel with an electrical component or device in a circuit when no load is connected (also known as a dummy load resistor). The main function of this type of resistor is to prevent the device from generating excessively high voltage under no-load conditions, thereby protecting the device from damage.

[0003] Currently, in applications such as power transmission, electric traction, and pulse power supplies, resistors that simultaneously possess characteristics such as high voltage, high power, high resistance, high heat dissipation efficiency, and good insulation withstand voltage to ground are required. However, due to limitations of existing technology, resistors currently on the market cannot simultaneously meet the application requirements of the above-mentioned multiple technical characteristics. In view of this, this utility model is proposed. Summary of the Invention

[0004] To overcome the above-mentioned defects, this utility model provides a water-cooled unloaded resistor, which integrates the advantages of high voltage, high power, high resistance, high heat dissipation efficiency, good insulation withstand voltage to ground, simple and reasonable structure, easy processing and manufacturing, and low manufacturing cost, thus well meeting market demand.

[0005] The technical solution adopted by this utility model to solve its technical problem is as follows: a water-cooled unloaded resistor, including a shell and a resistor assembly. The shell is a hollow, closed shell structure, with an inlet and an outlet for cooling water to flow in and out. The resistor assembly has multiple individual resistors, each with a thermally conductive resistor structure. Each individual resistor extends out of the shell with its two ends sealed. The individual resistors are connected in series and / or in parallel according to the product's electrical design requirements and have output terminals. Multiple baffles are spaced apart inside the shell to adjust the flow direction and flow rate of the cooling water inside the shell. A cover is provided outside the shell, sealing the ends of the individual resistors, and an insulating material layer is filled between the cover and the shell. In addition, the output terminals extend out of the cover.

[0006] As a further improvement of this utility model, each of the resistor units includes a metal outer shell, a resistor core assembly consisting of a resistor core and two terminals respectively fixedly connected to both ends of the resistor core, a thermally conductive filler, and two sealing heads. The resistor core assembly is inserted into the metal outer shell, while the two terminals respectively extend out of the opposite ends of the metal outer shell. The thermally conductive filler is tightly filled between the resistor core and the inner wall of the metal outer shell, and the two sealing heads are respectively sealed at the opposite ends of the metal outer shell. At the same time, the two sealing heads are also tightly wrapped around the two terminals.

[0007] As a further improvement of this utility model, the metal outer shell is a hollow cylindrical rod structure with openings at both ends in the length direction, and correspondingly, the two wiring terminals extend out of both ends in the length direction of the metal outer shell.

[0008] In addition, the thermally conductive filler is made of magnesium oxide, and the sealing head is made of epoxy resin.

[0009] As a further improvement of this utility model, multiple resistors are arranged in rows and columns within the outer casing, and the row and column directions of the multiple resistors are perpendicular to the length direction of the metal outer casing.

[0010] As a further improvement of this utility model, the terminals of the multiple resistor units are electrically connected to the output terminal after being connected by wires or copper busbars.

[0011] As a further improvement of this utility model, the output terminal adopts a wire or copper busbar; the output terminal is configured as two, and is respectively located on the same side or opposite sides of the housing.

[0012] As a further improvement of this utility model, the water inlet and the water outlet are spaced apart along the length direction of the metal outer shell, and correspondingly, the plurality of water baffles are also spaced apart along the length direction of the metal outer shell.

[0013] In addition, each of the water baffles is provided with multiple perforations for the resistor cells to pass through and multiple water passages for cooling water to pass through.

[0014] As a further improvement of this utility model, the cover is configured as two, and is respectively fixedly disposed on opposite sides of the outer shell.

[0015] As a further improvement of this utility model, the insulating material layer is made of epoxy resin or silicone rubber.

[0016] As a further improvement of this utility model, an installation component is fixedly provided on the outer wall of the outer shell.

[0017] The beneficial effects of this utility model are: ① By connecting multiple resistors, each with a thermally conductive resistive structure, in series and parallel to form the resistor assembly, the requirements of high voltage, high power, and high resistance values ​​can be well met. Simultaneously, the heat generated inside the resistors can be quickly and effectively dissipated, resulting in high heat dissipation efficiency. Furthermore, by adjusting the flow direction and flow rate of the cooling water using the baffle plate, the heat dissipated by the resistor assembly can be quickly and efficiently carried away and removed, ensuring the water-cooled unloaded resistor can operate normally for extended periods. ② By encapsulating the ends of the resistor assembly and the output terminals with insulating material, the insulation withstand voltage performance to ground of the water-cooled unloaded resistor can be effectively guaranteed. ③ The water-cooled unloaded resistor has a simple, reasonable, and flexible structure, is easy to process and manufacture, and has low manufacturing costs, facilitating production implementation. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of the water-cooled unloaded resistor described in Embodiment 1 of this utility model;

[0019] Figure 2 for Figure 1 A three-dimensional structural diagram of the water-cooled unloaded resistor shown in the image from another perspective;

[0020] Figure 3 for Figure 1 The diagram shows the main structural view of the water-cooled unloaded resistor shown in the figure.

[0021] Figure 4 for Figure 3 A schematic diagram of the AA cross-sectional structure of the water-cooled unloaded resistor shown in the figure.

[0022] Figure 5 for Figure 3 A schematic diagram of the BB cross-sectional structure of the water-cooled unloaded resistor shown in the figure;

[0023] Figure 6 for Figure 5 An enlarged structural diagram of section C shown in the figure;

[0024] Figure 7 for Figure 1 A partial structural schematic diagram of the water-cooled unloaded resistor shown in the figure;

[0025] Figure 8 for Figure 7 A schematic diagram of the cross-sectional structure of the resistor unit shown;

[0026] Figure 9 for Figure 7 A schematic diagram of the structure of the water baffle shown in the figure;

[0027] Figure 10 This is a three-dimensional structural diagram of the water-cooled unloaded resistor described in Embodiment 2 of this utility model;

[0028] Figure 11 for Figure 10 The diagram shows the installation status of the water-cooled unloaded resistor.

[0029] Referring to the accompanying drawings, the following explanations are provided:

[0030] 1. Outer casing; 10. Inlet; 11. Outlet; 2. Resistor assembly; 20. Individual resistor; 200. Metal outer casing; 201. Resistor core; 202. Terminal block; 203. Thermally conductive filler; 204. Sealing head; 21. Output terminal; 3. Water baffle; 30. Perforation; 31. Water passage hole; 4. Cover; 5. Insulation material layer; 6. Mounting components; 7. Frame. Detailed Implementation

[0031] The preferred embodiments of this utility model will be described in detail below with reference to the accompanying drawings.

[0032] Example 1:

[0033] Please see the appendix Figure 1 To be continued Figure 9 As shown, this embodiment 1 provides a water-cooled unloaded resistor, mainly including a housing 1 and a resistor assembly 2. The housing 1 is a hollow, closed shell structure, and has an inlet 10 and an outlet 11 for cooling water (specifically fresh water or deionized water) to flow in and out. That is, the housing 1 can provide installation and water cooling conditions for the resistor assembly 2. The resistor assembly 2 has multiple resistor cells 20, all of which adopt thermally conductive resistor structures. The multiple resistor cells 20 are all installed in the housing 1 with their two ends sealed and extending out of the housing 1. The multiple resistor cells 20 are also connected in series and / or in parallel according to the product electrical design requirements to lead out an output terminal 21. That is, by optimizing the configuration quantity and electrical connection method of the resistor cells 20, the product requirements of high voltage, high power, and high resistance can be well met. In addition, multiple baffles 3 are spaced apart inside the outer casing 1 to adjust the flow direction and flow rate of cooling water inside the outer casing 1 (which also indirectly achieves water pressure regulation), effectively realizing water cooling of the resistor assembly 2; and a cover 4 is provided outside the outer casing 1, which is sealed to both ends of the multiple resistor units 20, and an insulating material layer 5 is filled between the cover 4 and the outer casing 1 to ensure the insulation withstand voltage performance of the unloaded resistor to ground; furthermore, based on the configuration of the cover 4, the output terminal 21 extends out of the cover 4 in a sealed manner to realize the connection of the water-cooled unloaded resistor with other electrical components.

[0034] The specific structure of the water-cooled unloaded resistor described in Embodiment 1 is described in detail below.

[0035] First, let's explain the resistor set 2.

[0036] In the resistor set 2 described in this embodiment 1, the preferred implementation structure of the individual resistor 20 is as follows: Please refer to the appendix. Figure 4 and attached Figure 8 As shown, each resistor unit 20 includes a metal outer shell 200, a resistor core assembly consisting of a resistor core 201 and two terminals 202 respectively fixedly connected to both ends of the resistor core 201, a thermally conductive filler 203, and two sealing heads 204. The metal outer shell 200 is a hollow cylindrical rod structure made of 316L stainless steel and open at both ends along its length. The resistor core assembly passes through the metal outer shell 200, and the resistor core assembly and the metal outer shell 200 are arranged coaxially. The two terminals... 202 extends out of both ends of the metal housing 200 along its length; the thermally conductive filler 203 is made of magnesium oxide and is tightly filled between the resistor core 201 and the inner wall of the metal housing 200; the two sealing heads 204 are made of epoxy resin and are sealed at both ends of the metal housing 200 along its length through a potting process; at the same time, the two sealing heads 204 are also tightly wrapped around the two terminals 202 in part, that is, the opposite ends of the two terminals 202 are exposed outside the two sealing heads 204.

[0037] Compared to traditional heat-dissipating resistor structures (i.e., resistors with internal ceramic heat sinks and external aluminum heat sinks), the resistor unit 20 provided in Embodiment 1 adopts a thermally conductive resistor structure, which has the following advantages: ① Using magnesium oxide filler with high thermal conductivity, high temperature resistance, and high pressure resistance to conduct / dissipate heat for the resistor core can effectively ensure uniform heat dissipation and high heat dissipation efficiency, thereby significantly improving the power of the resistor unit and expanding its application range. ② By encapsulating the sealing head with epoxy resin material, the voltage withstand rating of the resistor unit to ground can be greatly improved. ③ The small size of the resistor unit not only allows for minimal partial discharge and improves the resistance to instantaneous current, but also facilitates modular / integrated product design and assembly. In summary, the resistor unit 20 provided in Embodiment 1 has advantages such as high heat dissipation efficiency, high power, high voltage resistance, small size, low partial discharge, modular / integrated design capability, and long service life. It can be used for a long time under harsh external environmental conditions and has a wide range of applications.

[0038] Furthermore, based on the small size and modular / integrated design capabilities of the individual resistor 20, multiple individual resistors 20 in the resistor assembly 2 are arranged in rows and columns within the outer casing 1, with the row and column directions of the multiple individual resistors 20 perpendicular to the length direction of the metal outer casing 200. It is understood that... Figure 7 Based on the placement of the resistor set 2 shown, the length direction of the metal casing 200 is the front-to-back direction, and multiple resistor units 20 are arranged in rows along the left-to-right direction and in columns along the up-down direction.

[0039] Furthermore, in the resistor set 2, the terminals 202 of the multiple resistor units 20 are connected to the output terminal 21 via wires or copper busbars.

[0040] Furthermore, in this embodiment 1, the output terminal 21 is a wire, and two output terminals 21 are configured and respectively disposed on the same side of the outer casing 1; see attached drawing for details. Figure 1 To be continued Figure 4 Appendix Figure 7 As shown. Additional explanation: Because the output terminal 21 uses a wire, it needs to be covered with an insulating silicone rubber sleeve to protect the wire and improve insulation protection.

[0041] Next, the water baffle 3, the cover 4, and the insulating material layer 5 will be described.

[0042] Please continue to refer to the appendix. Figure 2 As shown, based on the arrangement of the multiple resistor cells 20, the water inlet 10 and the water outlet 11 are designed to be spaced apart along the length of the metal casing 200, and the multiple baffles 3 are also designed to be spaced apart along the length of the metal casing 200. It can be understood that the cooling water can be basically regarded as flowing along the length of the metal casing 200 to better achieve water cooling of the resistor cells 20.

[0043] Furthermore, to better utilize the function of the baffle plate 3, multiple baffle plates 3 are arranged between the extension line of the center line of the inlet 10 and the extension line of the center line of the outlet 11.

[0044] Furthermore, each of the aforementioned baffle plates 3 is a plate-shaped structure made of 316L stainless steel, and the baffle plate 3 is provided with multiple through holes 30 for the resistor unit 20 to pass through and multiple water passage holes 31 for cooling water to pass through. (See attached drawing for details.) Figure 9 As shown.

[0045] Please continue to refer to the appendix. Figure 4 To be continued Figure 7 As shown, in this embodiment 1, the cover 4 is configured as two and is fixedly disposed on opposite sides of the outer shell 1. Specifically, the two covers 4 are fixedly disposed on opposite sides of the outer shell 1 along the length direction of the metal outer shell 200; correspondingly, the two output terminals 21 extend out from the same side of one of the covers 4.

[0046] Furthermore, both of the housings 4 and the outer shell 1 are made of 316L stainless steel, and the insulating material layer 5 is encapsulated between the opposite sides of the two housings 4 and the outer shell 1, as shown in the appendix. Figure 5 and attached Figure 6 As shown, the insulating material layer 5 can preferably be made of epoxy resin or silicone rubber.

[0047] Please continue to refer to the appendix. Figure 1 To be continued Figure 3 As shown, multiple mounting parts 6 (specifically L-shaped brackets) are fixedly installed on the outer wall of the housing 1. By means of the multiple mounting parts 6, the water-cooled unloaded resistor can be installed as a whole on a frame or other load-bearing structure.

[0048] As can be seen from the above, the water-cooled unloaded resistor described in Embodiment 1 has the following advantages: ① By connecting multiple individual resistors, all with thermally conductive resistive structures, in series and parallel to form the resistor assembly, it can effectively meet the product requirements of high voltage, high power, and high resistance, while also quickly and effectively dissipating the heat generated inside the individual resistors, resulting in high heat dissipation efficiency. Furthermore, by adjusting the flow direction and flow rate of the cooling water using the baffle plate, the heat dissipated by the resistor assembly can be quickly and efficiently carried away and removed, thus ensuring that the water-cooled unloaded resistor can operate normally for extended periods. ② By encapsulating the ends of the resistor assembly and the output terminals with insulating material, the insulation withstand voltage performance of the water-cooled unloaded resistor to ground can be effectively guaranteed. ③ The water-cooled unloaded resistor has a simple, reasonable, and flexible structure, is easy to process and manufacture, and has low manufacturing costs, facilitating production implementation.

[0049] Example 2:

[0050] This embodiment 2 also provides a water-cooled unloaded resistor, and compared with embodiment 1, the water-cooled unloaded resistor in this embodiment 2 has the following main differences: ① The specific structure and arrangement of the output terminal 21 in the water-cooled unloaded resistor in this embodiment 2 are different from those in embodiment 1.

[0051] For details, please refer to the appendix. Figure 10As shown, in the water-cooled unloaded resistor described in Embodiment 2, the output terminal 21 is made of copper busbar (specifically, pure copper), and two output terminals 21 are configured and respectively disposed on opposite sides of the outer casing 1. Furthermore, the two output terminals 21 extend out of the two covers 4 respectively. Note: When the output terminal 21 is made of copper busbar, it needs to be tin-plated on its surface to achieve corrosion resistance, improve wear resistance, and enhance conductivity.

[0052] Additionally, please see the appendix. Figure 10 and attached Figure 11 As shown in this embodiment 2, a plurality of mounting parts 6 (specifically L-shaped brackets) are also fixedly installed on the outer wall of the housing 1, and the water-cooled unloaded resistor is fixedly installed on the frame 7 through the plurality of mounting parts 6.

[0053] Note: Except for the difference ① mentioned above, other components in the water-cooled unloaded resistor structure described in this embodiment 2, such as the outer shell 1, resistor unit 20, water baffle 3, cover 4, insulating material layer 5, etc., all adopt the same technical means as in embodiment 1, so they will not be described in detail here.

[0054] As can be seen from the above, the water-cooled unloaded resistor provided in this embodiment 2 also integrates the advantages of high voltage, high power, high resistance, high heat dissipation efficiency, good insulation withstand voltage to ground, simple and reasonable structure, easy processing and manufacturing, and low manufacturing cost, which well meets the market demand.

[0055] Many specific details have been set forth in the above description to provide a full understanding of this utility model. However, the above description is only a preferred embodiment of this utility model, and this utility model can be implemented in many other ways different from those described herein. Therefore, this utility model is not limited to the specific embodiments disclosed above. Furthermore, any person skilled in the art can make many possible variations and modifications to the technical solution of this utility model using the methods and techniques disclosed above, or modify it into equivalent embodiments with equivalent changes, without departing from the scope of the technical solution of this utility model. Any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of this utility model, without departing from the content of the technical solution of this utility model, shall still fall within the protection scope of the technical solution of this utility model.

Claims

1. A water-cooled unloaded resistor, characterized in that: The device includes a housing (1) and a resistor assembly (2). The housing (1) is a hollow, closed shell structure. The housing (1) is provided with an inlet (10) and an outlet (11) for cooling water to flow in and out. The resistor assembly (2) is provided with multiple resistor units (20) that are all thermally conductive resistors. The multiple resistor units (20) are all installed in the housing (1) with their two ends sealed and extending out of the housing (1). The multiple resistor units (20) are also connected in series and / or in parallel according to the electrical design requirements of the product and have output terminals (21) led out. Multiple baffles (3) are spaced apart inside the housing (1) to adjust the flow direction and flow rate of cooling water inside the housing (1); and a cover (4) is provided outside the housing (1) to seal the ends of multiple resistor units (20), and an insulating material layer (5) is filled between the cover (4) and the housing (1); in addition, the output terminal (21) extends out of the cover (4).

2. The water-cooled unloaded resistor according to claim 1, characterized in that: Each resistor unit (20) includes a metal outer shell (200), a resistor core assembly consisting of a resistor core (201) and two terminals (202) respectively fixedly connected to both ends of the resistor core (201), a thermally conductive filler (203), and two sealing heads (204). The resistor core assembly is inserted into the metal outer shell (200), and the two terminals (202) extend out of the opposite ends of the metal outer shell (200). The thermally conductive filler (203) is tightly filled between the resistor core (201) and the inner wall of the metal outer shell (200). The two sealing heads (204) are respectively sealed on the opposite ends of the metal outer shell (200), and the two sealing heads (204) are also tightly wrapped around the two terminals (202) in parts.

3. The water-cooled unloaded resistor according to claim 2, characterized in that: The metal outer shell (200) is a hollow cylindrical rod structure with openings at both ends along its length. Correspondingly, the two terminals (202) extend out of the two ends along the length of the metal outer shell (200). In addition, the thermally conductive filler (203) is made of magnesium oxide filler, and the sealing head (204) is made of epoxy resin material.

4. The water-cooled unloaded resistor according to claim 3, characterized in that: Multiple resistors (20) are arranged in rows and columns within the outer casing (1), and the row and column directions of the multiple resistors (20) are perpendicular to the length direction of the metal outer casing (200).

5. The water-cooled unloaded resistor according to claim 2, characterized in that: The terminals (202) of the multiple resistor units (20) are connected to the output terminal (21) via wires or copper busbars.

6. The water-cooled unloaded resistor according to claim 5, characterized in that: The output terminals (21) are made of wires or copper busbars; the output terminals (21) are configured as two, and are respectively located on the same side or opposite sides of the housing (1).

7. The water-cooled unloaded resistor according to claim 3, characterized in that: The inlet (10) and the outlet (11) are spaced apart along the length of the metal outer shell (200), and correspondingly, the multiple baffles (3) are also spaced apart along the length of the metal outer shell (200). In addition, each of the water baffles (3) is provided with a plurality of perforations (30) through which the resistor unit (20) passes and a plurality of water passages (31) through which cooling water passes.

8. The water-cooled unloaded resistor according to claim 4, characterized in that: The cover (4) is configured as two, and is fixedly disposed on opposite sides of the outer shell (1).

9. The water-cooled unloaded resistor according to claim 1, characterized in that: The insulating material layer (5) is made of epoxy resin or silicone rubber.

10. The water-cooled unloaded resistor according to claim 1, characterized in that: An installation component (6) is fixedly installed on the outer wall of the outer casing (1).

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