Ripple Resistor

The Wirewound Resistor (BWR) is a type of power resistor. Its core design feature is the vertical wave-like (corrugated) winding of the resistance wire around a ceramic tube. This unique structure enhances heat dissipation by increasing the surface area, allowing it to efficiently convert electrical energy-particularly the regenerative energy generated during motor braking-into thermal energy for dissipation. It is primarily used in industrial electrical control applications that require high-power dissipation.

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Working Principle and Core Function

The Wirewound Resistor operates based on Joule's Law: when an electric current passes through the resistance wire, electrical energy is directly converted into thermal energy. Its corrugated design enhances the speed and stability of heat dissipation by increasing the heat dissipation surface area and reducing parasitic inductance.

A key function in industrial applications is "dynamic braking." When a motor controlled by a variable-frequency drive (VFD) requires rapid stopping, a substantial amount of regenerative energy is generated due to inertia and feeds back into the VFD's DC circuit, posing a risk to equipment safety. By connecting the Wirewound Resistor at this stage, this excess electrical energy can be converted into heat and dissipated, thereby protecting the VFD and maintaining grid voltage stability.

Main Application Areas

Thanks to their high power-handling capacity and reliable heat dissipation, Wirewound Resistors are widely used in the following areas:

Industrial Automation & Motor Control: Employed in the braking units of variable-frequency drives (VFDs) and servo systems, as well as for current limiting during motor startup and speed regulation.

Power Supplies & Power Electronics: Utilized in power supply circuits for functions such as current limiting, voltage division, and voltage stabilization.

Testing & Discharge Circuits: Serve as load resistors for equipment testing or in discharge circuits for components like capacitors.

Other Fields: Also commonly found in the electrical systems of equipment such as hoisting machinery, elevators, welding machines, and rail transit systems.

Our production system is equipped with industry-advanced specialized machinery and automated systems, dedicated to the precision manufacturing of high-performance wirewound resistors. This ensures that our products meet stringent industrial application standards in terms of power density, stability, and long-term durability.

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