Coil Nichrome Load Resistor for Compact Emergency Generator Testing
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Solution Overview
Problem
Conventional load resistors used for emergency generator tests generate excessive heat, requiring large and heavy cooling devices to maintain safety, which occupy significant weight and volume.
Innovation Solution
A load resistor design featuring a rod-shaped resistor body with a nichrome wire wound into a coil form, stretched to increase surface area, and inserted into a pipe-shaped protecting material with an insulating member, allowing for efficient heat dissipation without the need for a large cooling device, using a fan or other forced cooling methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional resistor rods are used to generate heat for emergency generator testing, then the heat generation capability is sufficient, but the temperature rises to 400-600°C requiring large cooling devices
Solution Approach 1:
The patent changes the physical parameters of the resistor by winding it into a coil shape, which fundamentally alters the heat distribution characteristics. This transformation reduces the temperature from 400-600°C to approximately 100°C or less, eliminating the need for heavy cooling devices while maintaining the heat generation capability for emergency generator testing
2Temperature
If conventional resistor rods are used to generate heat for emergency generator testing, then the heat generation capability is sufficient, but the temperature rises to 400-600°C requiring large cooling devices
Solution Approach 1:
By transforming the resistor into a coil shape, the patent fundamentally changes the thermal characteristics. The temperature reduction to approximately 100°C or less eliminates the need for large-volume cooling devices, thereby reducing the overall volume of the testing equipment while maintaining effective heat generation
3Power
If resistor rods are arranged to generate sufficient heat, then the heat generation capability is adequate, but the heat concentrates in agglomerates reaching 400-600°C
Solution Approach 1:
The patent segments the resistor into a coil structure with multiple turns, which distributes the heat generation along the entire coil length rather than concentrating it in a single location. This segmentation maintains the total heat generation power while preventing localized temperature spikes to 400-600°C, keeping the temperature at approximately 100°C or less
Solution Approach 2:
By transforming the resistor from a linear rod to a three-dimensional coil structure, the patent distributes heat generation across multiple spatial dimensions. This dimensional transformation allows the heat to be dispersed along the coil's length and volume, preventing concentration in agglomerates while maintaining adequate total power output
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design limits heat generation to approximately 100° C or less, eliminating the need for heavy cooling devices and enabling a more compact and lightweight load resistor that can perform tests safely without forced cooling.
Implementation Method 1
a rod-shaped resistor base body configured to be energized by the electric power to generate a heat
Implementation Method 2
an insulating member filled between the rod-shaped resistor base body and the protecting material
Data Source
AI summary
The present invention is a load resistor that receives power transmitted from an apparatus and performs an energization test on the apparatus. The load resistor is characterized by comprising a rod-shaped resistive base body that is energized with the power and generates heat, a pipe-shaped protective member through which the rod-shaped resistive base body penetrates, and rod-shaped resistors having an insulation member that are packed in between the rod-shaped resistive base body and the protective member, the rod-shaped resistive base body having used therein a stretched nichrome wire that is wound in the shape of a coil.