Cylindrical Dynamic Braking Resistors With Fluid-Cooled Openings
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Solution Overview
Problem
Existing resistors are limited in their heat dissipation capacity, which restricts their ability to efficiently manage electric current in powered systems such as braking and power-generating systems, as they often rely on planar designs that do not effectively utilize cooling fluids for heat dissipation.
Innovation Solution
The development of elongated cylindrical resistors with nodes and elongated members that form openings for cooling fluid flow, allowing for enhanced heat dissipation through additive manufacturing techniques using materials like nickel alloys, which increase the surface area and enable more efficient cooling, and can be connected in series or parallel configurations for increased reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If planar or flat plate designs are used for resistors, then the surface area exposure to ambient environment is increased for cooling, but the heat dissipation capacity is limited
Solution Approach 1:
The patent transitions from two-dimensional planar resistor designs to three-dimensional cylindrical resistor structures. The cylindrical body with radially extending fins creates a multi-dimensional heat dissipation architecture that increases surface area volume ratio, allowing more efficient heat transfer to the cooling fluid flowing through the central bore and across the fin surfaces.
Solution Approach 2:
The resistor body incorporates a porous structure with a central bore and multiple radial passages that allow cooling fluid to flow through the interior. This porous architecture increases the contact area between the hot resistor material and the cooling fluid, enhancing convective heat transfer while maintaining structural integrity for electrical conduction.
2Temperature
If traditional resistor designs are used, then manufacturing simplicity is maintained, but heat dissipation efficiency is insufficient
Solution Approach 1:
The patent modifies key geometric parameters of the resistor structure, including the cylindrical body dimensions, fin radial extensions, and internal passage configurations. These parameter changes optimize the surface area to volume ratio and fluid flow characteristics, significantly improving heat dissipation efficiency while remaining compatible with conventional manufacturing processes like casting or extrusion.
3Temperature
If resistor size is increased to improve heat dissipation, then heat dissipation capacity is enhanced, but weight and space requirements increase
Solution Approach 1:
The cylindrical finned design with internal passages creates a three-dimensional heat dissipation structure that achieves high surface area within a compact volume. This dimensional optimization allows the resistor to dissipate more heat without proportionally increasing weight or space occupation, as the heat dissipation capacity scales with surface area while mass scales with volume.
Solution Approach 2:
The porous internal structure with cooling passages allows the resistor to achieve high heat dissipation capacity without requiring solid material throughout the entire volume. The strategic placement of passages and fins creates efficient heat transfer pathways while reducing overall material usage and weight compared to solid block designs of equivalent heat dissipation capability.
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 new resistor design significantly enhances heat dissipation capacity, increases the useful life and reliability of resistors, and reduces weight and space requirements, while allowing for effective cooling using air or other fluids, thereby improving the performance of powered systems.
Implementation Method 1
The body may receive electric current from a powered system and to conduct and provide electric resistance to the electric current to dissipate at least part of the electric current as heat from the body
Implementation Method 2
The elongated members interconnect the nodes to form openings between the nodes and the elongated members for the flow therethrough of a cooling fluid
Data Source
AI summary
A resistor includes an elongated cylindrical body having nodes and elongated members. The elongated members interconnect the nodes to form openings between the nodes and the elongated members for the flow therethrough of a cooling fluid. The body is configured to receive electric current from a powered system and to conduct and provide electric resistance to the electric current to dissipate at least part of the electric current as heat from the body. The body may be coupled with at least one other resistor of the powered system in one or more of a parallel or series arrangement in an electric circuit.