Stacked Power Resistor With 90-Degree Plate Rotation
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Solution Overview
Problem
Electric power resistors with meandering structures face mechanical stability issues due to expansion forces caused by magnetic repulsion between transverse webs, requiring additional holders for stabilization.
Innovation Solution
The resistor plates are arranged with alternating 90° rotations along the stack direction, allowing transverse webs and end connector webs to absorb expansion forces, reducing mechanical demands on the fastening device and enabling a simple, inexpensive design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If resistor plates are arranged in a stack with meandering structures, then electrical energy conversion is achieved, but mechanical stability deteriorates due to expansion forces from magnetic repulsion
Solution Approach 1:
The patent applies asymmetry by rotating alternate resistor plates by 90 degrees relative to adjacent plates. This asymmetric arrangement causes expansion forces from magnetic repulsion to act in different directions on adjacent plates, allowing transverse webs and end connector webs to absorb these forces mutually, thereby maintaining mechanical stability while preserving electrical energy conversion functionality.
Solution Approach 2:
The patent introduces a rotational dimension to the stack arrangement. By rotating alternate plates by 90 degrees around the stack axis, the expansion forces that would normally act in one dimension are redistributed across multiple dimensions, allowing the structure to self-stabilize without requiring additional external holders.
2Stability of the object's composition
If additional holders or fastening devices are used to stabilize resistor plates, then mechanical stability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent implements self-service by designing the resistor plates themselves to provide mutual stabilization through their rotated arrangement. The transverse webs and end connector webs of adjacent plates absorb each other's expansion forces, making the structure self-stabilizing without requiring external holders or complex fastening devices.
Solution Approach 2:
The patent merges the electrical resistance function with the mechanical stabilization function into a single integrated structure. The same transverse webs and end connector webs that provide electrical connectivity also serve to absorb and distribute mechanical expansion forces, eliminating the need for separate stabilization components.
3Ease of manufacture
If resistor plates are made flexible to accommodate magnetic repulsion, then ease of manufacture is improved, but mechanical stability deteriorates due to plate expansion
Solution Approach 1:
The asymmetric rotation of alternate plates by 90 degrees transforms the stability problem. The flexibility of individual plates is maintained for ease of manufacture, while the asymmetric arrangement ensures that expansion forces are distributed and absorbed by adjacent plates, preventing cumulative deformation and maintaining overall shape stability of the resistor unit.
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
This configuration provides enhanced mechanical stability and flexibility in design, allowing for self-supporting structures without external holders, while maintaining electrical conductivity and insulation, thus improving the overall stability and usability of the resistor units.
Implementation Method 1
If namely an electric current flows through the respective resistor plate, the current flows in opposite directions in mutually adjacent transverse webs. The interaction of the magnetic fields induced in the adjacent transverse webs results in a mutual repulsion of the transverse webs.
Implementation Method 2
The transverse webs and/or the end connector webs of a respective resistor plate provided at the ends of the meandering structure and extending in parallel to the transverse webs can hereby take up the repulsion and expansion forces of an adjacent resistor plate (rotated by 90°).
Implementation Method 3
an electric power resistor which serves for converting electric energy into thermal energy in special operating states in electric plants
Data Source
AI summary
An electric power resistor has a stack of a plurality of resistor plates of metal. Each resistor plate has at least one meandering structure which is formed by a plurality of alternately mutually connected transverse webs. Resistor plates following one another in the stack direction are rotated by 90° with respect to one another.