CN112820487A - 一种大功率型水冷线绕固定电阻器 - Google Patents
一种大功率型水冷线绕固定电阻器 Download PDFInfo
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- CN112820487A CN112820487A CN202010765366.3A CN202010765366A CN112820487A CN 112820487 A CN112820487 A CN 112820487A CN 202010765366 A CN202010765366 A CN 202010765366A CN 112820487 A CN112820487 A CN 112820487A
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- water
- fixed resistor
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- waterway
- cooling
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- 238000001816 cooling Methods 0.000 title claims abstract description 17
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- H01C1/082—Cooling, heating or ventilating arrangements using forced fluid flow
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- H—ELECTRICITY
- H01—BASIC ELECTRIC ELEMENTS
- H01C—RESISTORS
- H01C17/00—Apparatus or processes specially adapted for manufacturing resistors
- H01C17/02—Apparatus or processes specially adapted for manufacturing resistors adapted for manufacturing resistors with envelope or housing
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- H—ELECTRICITY
- H01—BASIC ELECTRIC ELEMENTS
- H01C—RESISTORS
- H01C17/00—Apparatus or processes specially adapted for manufacturing resistors
- H01C17/04—Apparatus or processes specially adapted for manufacturing resistors adapted for winding the resistive element
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- H—ELECTRICITY
- H01—BASIC ELECTRIC ELEMENTS
- H01C—RESISTORS
- H01C17/00—Apparatus or processes specially adapted for manufacturing resistors
- H01C17/28—Apparatus or processes specially adapted for manufacturing resistors adapted for applying terminals
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- H—ELECTRICITY
- H01—BASIC ELECTRIC ELEMENTS
- H01C—RESISTORS
- H01C3/00—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids
- H01C3/14—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids the resistive element being formed in two or more coils or loops continuously wound as a spiral, helical or toroidal winding
Abstract
本发明名称为一种大功率型水冷线绕固定电阻器，属于水冷电阻器领域。该大功率型水冷线绕固定电阻器包括双并联等截面直立水路主板、侧板、波纹合金带、金属电极、水路填块、密封圈等，其特征在于双并联等截面直立水路主板的设计可增加水路长度，减小对电阻带强度的要求，降低水阻。本发明专利的优点是提供一种体积小、功率大、耐水压、耐脉冲能力强、断水性能好，性能更加可靠的电阻器结构。以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到的变化或替换，都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应该以权利要求的保护范围为准。
Description
所属技术领域 本发明属于水冷电阻器领域。 背景技术 现有的水冷电阻器大多采用如下结构：采用螺旋式水道设计，电阻带紧贴两个侧壁。当出现断水情况或功率异常增大时，处于顶部的波纹合金带会被气泡包裹，出现烧断现象。 该类电阻器存在以下缺陷： 1、断水性能差； 2、耐功率负荷能力差。 发明内容 为解决上述方案中存在的缺陷，本发明提供了一种大功率型水冷线绕固定电阻器及其制作方法。 本发明是通过以下技术方案实现的： 本发明所涉及的是一种大功率型水冷线绕固定电阻器，主要包括1个波纹合金带电阻芯，1个双排并联等截面直立水路主板，2个侧板，2个水路填块，2个耐腐蚀的金属电极，2个密封圈，2个螺母，2个平垫和2个弹垫。 在双排并联等截面直立水路主板两侧开有对称的开口水槽，开口水槽由直立主水槽和连接直立水槽的弧形水槽组成，两侧的水槽接成并联水路，共有一个进水口和一个出水口；在侧板的一侧开有和等截面直立水路主板上的开口水槽相应的开口水槽。先将波纹合金带按水路走向盘绕在开口水槽中，波纹合金带两端分别和2个金属电极焊接在一起，形成波纹合金电阻芯。 在金属电极密封槽内放入密封圈，然后穿过双排并联等截面直立水路主板，再依次安装平垫、弹垫和螺母进行固定；最后在双排并联等截面水路主板的电极槽内安装2个水路填块，避免通水时在此处形成漩涡。 双排并联等截面直立水路主板和侧板开口槽两侧均有凸出的焊线，通过焊接机将焊接线熔化后加压，焊接在一起，水路截面的宽度尺寸与深度尺寸的比值小于0.3。 工作时，先开冷却水，再通过外电极对波纹合金带电阻芯施加功率，水从双排并联等截面直立水路主板进水口进入，流过各段水路并将浸在水路中的波纹合金带电阻芯产生的热量带走。 该方案的优点是： 1、水路采用垂直向上的设计方案，相邻直立水路顶部之间的弧形连接水路处于水路的最高位置，波纹合金带从弧形连接水路最底部穿过，出现停水故障时波纹合金带电阻芯仍在通电，周围的水温迅速升高并伴有气泡，气泡会沿着直立水路迅速升到弧形连接水路顶部，在顶部形成一个气室，从而保证了各处波纹合金带电阻芯始终被水包裹，在规定的停水时间内不被烧坏。 2、水路内部设计了二次冷却水路，可以更好地降低波纹合金带的最高工作温度，提高产品的耐负荷能力。 所述等截面直立水路合金带水冷电阻器制作方法： 1、制作双排并联等截面直立水路主板：加工出双排并联等截面直立水路主板模具，用该模具注塑出双排并联等截面直立水路主板； 2、制作侧板：加工出侧板模具，用该模具注塑出侧板； 3、制作波纹合金带：用绕带设备加工出波纹状的波纹合金带； 4、制作波纹合金带电阻芯：将波纹合金带按水路走向盘绕在水路中，波纹合金带两端头分别和2个金属电极焊接在一起形成波纹合金电阻芯； 5、电极安装：在金属电极密封槽内放入密封圈，穿过双排并联等截面直立水路主板，再依次安装平垫、弹垫和螺母进行固定，以保证通水时的密封性能； 6、水路填块安装：将水路填块安装到双排并联等截面直立水路主板的电极槽内，避免通水时在此处形成漩涡； 7、焊接侧板：将2个侧板焊接在双排并联等截面直立水路主板两侧，便加工完成一个大功率型水冷线绕固定电阻器。 本发明的有益效果是： 大功率型水冷线绕固定电阻器体积小，结构简单，断水性能好、耐负荷能力强。在水温为45℃时，给电阻器充满水后施加2000W的功率，同时关闭进出水口阀门，电阻器可持续工作5s；在水流量3L/min，进水温度40℃时，可以实现6000W的额定功率。 附图说明 下面结合附图和实例对本发明作进一步说明： 图1是大功率型水冷线绕固定电阻器； 图2是双排并联等截面直立水路主板组装板示意图； 图3是双排并联等截面直立水路主板示意图； 图4是侧板(正面)示意图； 图5是侧板(背面)示意图； 图6是金属电极示意图； 图7是水路填块示意图； 图8是密封圈示意图； 图9是合金带示意图； 图10是波纹合金带示意图。 图中，1代表合金带；2代表波纹合金带；3代表金属电极；4代表水路填块；5代表密封圈；6代表双排并联等截面直立水路主板；7代表开口水槽；8代表二次冷却开口水槽；9代表水路填块安装槽；10代表电阻器安装孔；11代表电阻器安装螺柱；12代表焊接线；13代表进水口；14代表出水口；15代表侧板(正面)示意图；16代表侧板(背面)示意图。 具体实施方式 1、将图9合金带1加工成图10波纹合金带2； 2、将图10波纹合金带2缠绕在图3双排并联等截面直立水路主板的开口水槽7内，并将波纹带2的两端分别焊接在2个图6金属电极上； 3、将图8密封圈安装在图6金属电极的密封圈固定槽内，组成图2双排并联等截面直立水路主板组装板，其中包括2波纹合金带、3金属电极2个，4水路填块2个，5密封圈 2个； 4、将图4侧板(正面)和图5侧板(背面)，用焊接机焊接在双排并联等截面直立水路主板组装板两侧，组成图1是大功率型水冷线绕固定电阻器。 以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本领域的技术人员在本发明揭露的范围内，可轻易想到的变化或替换，都应涵盖在本发明的保护范围内。因此，本发明的保护范围应该以权利要求的保护范围为准。