Modular Current-Limiting Resistor Assembly for Uniform Cooling
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Solution Overview
Problem
Conventional current-limiting resistors face challenges in maintaining uniform welding quality, productivity, and cooling efficiency due to manual welding and natural cooling methods, which are affected by the skill level of operators and the number of stacked resistor pieces.
Innovation Solution
A modular current-limiting resistor design featuring unit modules with stacked plate resistors connected via fasteners, conductive and insulating rings, and spacers, allowing for easy resistance design and improved cooling through perpendicular stacking and natural convection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of stacked plate resistor pieces is increased to achieve higher resistance magnitude, then the resistance value is improved, but the welding time and productivity deteriorate
Solution Approach 1:
The current-limiting resistor is divided into multiple unit modules, each containing a predetermined number of plate resistor pieces (e.g., 5 pieces). This segmentation allows the resistor to be assembled by simply stacking pre-configured modules rather than individually welding each plate piece, thereby maintaining the required resistance magnitude while dramatically reducing assembly time and improving productivity.
2Ease of manufacture
If manual welding is used to connect plate resistor pieces, then the assembly is completed, but the welding quality uniformity deteriorates due to operator skill level variations
Solution Approach 1:
An insulator with built-in conductive portions is introduced as an intermediary component to connect adjacent plate resistor pieces. This insulator serves as a mediator that provides both electrical connection and insulation functions, eliminating the need for manual welding operations while ensuring uniform connection quality across all joints regardless of operator skill level.
3Reliability
If insulators are inserted between stacked plate resistor pieces to prevent contact, then the insulation is improved, but the cooling efficiency deteriorates as insulators block air flow
Solution Approach 1:
The insulator is designed with non-uniform structure: it has insulating portions positioned between plate resistor pieces to prevent electrical contact and ensure insulation, while simultaneously having conductive portions (made of heat-conductive material) positioned to facilitate heat dissipation and maintain air flow channels. This local differentiation of properties allows the insulator to perform both insulation and cooling functions effectively.
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
Enhances productivity by eliminating manual welding, ensures uniform welding quality, and improves cooling efficiency by facilitating air flow, making it easier to tailor resistance to specific power system requirements.
Implementation Method 1
a plurality of conductive rings, each being disposed between adjacent plate resistors, wherein the fastener passes through the conducive ring, wherein the conductive ring electrically connects conductive lines of the adjacent plate resistors to each other
Implementation Method 2
Cooling of the current-limiting resistor 1 relies on natural cooling due to flow of air
Data Source
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AI summary
The present invention relates to a modular current limiting resistor comprising: a plurality of plate resistors which are stacked on one another, wherein the plurality of plate resistors each comprise a pair of coupling pieces and a conducting line integrally formed with the coupling pieces and having a zigzag shape between the coupling pieces; a pair of support frames which respectively support the stacked plate resistors, on both sides of the stacked direction; a plurality of coupling members which pass through one of the support frames, pass the coupling pieces, and then are inserted into the plate resistors through the other one of the support frames so as to fix the plate resistors; a plurality of conductor rings which are disposed between the plurality of plate resistors while passing through and being inserted into the coupling members, and which electrically connect the conducting line on each of the plate resistors; and at least one unit module comprising a plurality of insulating rings which are disposed between the plurality of plate resistors while passing through and being inserted into the coupling members so as to insulate the plate resistors.