Spiral Electrical Resistor Compact High-Power Design
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Solution Overview
Problem
Conventional high-power electrical resistors require large dimensions, limiting their compactness and efficiency, and existing solutions do not effectively optimize cooling or modular assembly for high-power applications.
Innovation Solution
A compact electrical resistor design featuring a spiral resistive element with optimized cooling, allowing for effective fluid flow interaction and safe overload behavior, enabling high power per unit volume and modular assembly for easy production of high-power assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the dimensions of an electrical resistor are increased to achieve high power, then the power capacity is improved, but the compactness and volume efficiency deteriorate
Solution Approach 1:
The resistive element is arranged in a spiral configuration around a longitudinal axis, transforming a linear one-dimensional structure into a three-dimensional spiral form. This allows the resistive element to occupy space more efficiently, achieving high power capacity within a compact cylindrical housing by utilizing volumetric space rather than just linear extension
Solution Approach 2:
The spiral guide element is positioned within the housing, and the resistive element is arranged within the spiral guide element, creating a nested configuration. This nested arrangement allows multiple functional components to occupy overlapping spatial regions, maximizing the use of available volume while maintaining compact dimensions
2Power
If the length of the resistive element is increased to achieve high power, then the power capacity is improved, but the inductance increases
Solution Approach 1:
By arranging the resistive element in a spiral around a longitudinal axis rather than in a straight line, the patent achieves a longer effective resistive path within a compact volume. This spiral configuration reduces the loop area compared to a linear arrangement, thereby reducing inductance while maintaining the required power capacity
Solution Approach 2:
The spiral configuration introduces curvature to the resistive element path, replacing a straight linear arrangement with a curved three-dimensional path. This curvature optimizes the spatial distribution of current flow and reduces the magnetic field loop area, thereby reducing inductance while maintaining effective resistance length
3Power
If conventional cooling methods are used, then the structure is simple, but the cooling efficiency and power density are insufficient
Solution Approach 1:
The cooling fluid circulates in a spiral path around the resistive element, following the same spiral geometry. This three-dimensional spiral cooling path maximizes the surface area contact between the cooling fluid and the resistive element, enhancing heat transfer efficiency compared to conventional linear or planar cooling arrangements
Solution Approach 2:
The spiral guide element serves dual functions: it provides structural support for the resistive element and simultaneously guides the cooling fluid along an optimized spiral path. This merging of structural and cooling functions reduces the number of separate components while achieving superior cooling efficiency
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 compact design achieves high power per unit volume, safe overload behavior, and facilitates modular assembly, enhancing the production of high-power electrical assemblies like thyristor converters with reduced inductance and improved cooling efficiency.
Implementation Method 1
optimized cooling of the resistive element... the spiral guide element makes it possible to guide a flow of cooling fluid effectively over the entire length of the resistive element
Implementation Method 2
guide a flow of cooling fluid effectively over the entire length of the resistive element, optimizing the interaction between the resistive element and the flow of cooling fluid
Implementation Method 3
electrical resistor... power of an electrical resistor depends in particular on its dimensions... high-power electrical resistor
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The electrical resistor (10) comprises a sealed housing (12) of generally cylindrical shape defined along a longitudinal axis (X), a resistive element (16) extending along a spiral defined around the longitudinal axis (X), and a fluid guide element (18) which, together with the sealed housing (12), forms a fluid guide conduit for directing a fluid flow in contact with the resistive element (16). This guide element (18) has a spiral shape defined around the longitudinal axis (X).