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We offer a comprehensive portfolio including resistors, braking units, reactors, power filters, and transformers, with full customization options to meet diverse application requirements.
During the braking process of a variable frequency drive system, the motor may generate regenerative energy when the rotating speed decreases. If this energy cannot be consumed effectively, the DC bus voltage will rise and may trigger inverter protection.
Dufew Electric Braking Resistor Box is designed to work together with braking units to dissipate this excess energy through resistor elements. The internal corrugated resistors are assembled according to the required power and resistance values, while the metal enclosure provides mechanical protection and improves heat dissipation.
The integrated design combines resistor elements, connection terminals, and temperature protection components into one complete unit, simplifying installation and improving system reliability in industrial applications.
| Parameter | Specification |
|---|---|
| Rated Power | 1kW-30kW |
| Working Voltage | ≤1200V |
| Resistance Range | 0.01Ω-1kΩ |
| Resistance Tolerance | ±3%, ±5%, ±10% |
| Protection Grade | IP20 / IP23 (Customizable) |
| Temperature Coefficient | ≤300 ppm/℃ |
| Flame Retardant Grade | UL94V-2 |
| Standard | GB-5792 |
The internal corrugated resistor elements are professionally arranged and fixed inside the enclosure to provide stable electrical performance. The integrated design simplifies installation and eliminates the need for additional resistor assembly at the customer site.
The enclosure adopts ventilation openings and optimized internal spacing to improve airflow circulation. During short-time high-power braking cycles, the structure provides sufficient heat storage capacity and helps quickly release accumulated heat.
A temperature protection switch is installed close to the heating components. When the internal temperature exceeds the preset safety value, the protection system disconnects the circuit to reduce the risk of overheating.
The resistor box supports different installation methods, including floor mounting and equipment platform installation. Standard mounting holes make integration with industrial control systems easier.
- Designed for VFD braking applications: Matches common inverter braking systems to effectively handle regenerative energy.
- Stable overvoltage protection: Dissipates excess energy generated during motor deceleration and emergency stops.
- Strong pulse overload capability: Suitable for frequent acceleration, braking, and intermittent high-power operation.
- Modular resistor configuration: Supports customized power and resistance combinations according to operating conditions.
- Integrated protection design: Includes connection terminals and temperature protection components for safer operation.
- Reliable industrial performance: Suitable for heavy-duty equipment operating under continuous braking cycles.
Dufew braking resistor solutions are suitable for industrial equipment that requires controlled energy dissipation during deceleration, stopping, or dynamic load changes. They are commonly integrated into lifting systems, material handling equipment, industrial machinery, power electronics testing systems, and renewable energy applications.
For elevators, tower cranes, hoists, lifting platforms, and winches, the resistor absorbs regenerative energy generated during lowering and deceleration, helping the drive system maintain stable operation during frequent start-stop and load-changing cycles.
Belt conveyors, stacker reclaimers, and heavy transportation equipment often require controlled braking when handling large or moving loads. The resistor solution helps dissipate regenerative energy and supports reliable deceleration in continuous material handling operations.
Rolling mills, centrifuges, injection molding machines, CNC equipment, and other motor-driven machinery can generate substantial regenerative energy during rapid speed changes. Properly configured braking resistance helps improve stopping performance and protect the associated drive system.
The solution can also be integrated into high-power load testing systems and electrical equipment aging test platforms, where controlled resistance is required to simulate operating loads and evaluate equipment performance under defined conditions.
Wind power converters, rail transit traction systems, and energy management equipment may require reliable energy dissipation during braking, adjustment, or transient operating conditions. Customized resistance configurations can be matched to the voltage, power, and duty cycle requirements of these systems.
| Performance Item | Test Condition | Requirement |
|---|---|---|
| Dielectric Strength | 2500VAC, 50Hz/60S | Leakage current ≤10mA |
| Insulation Resistance | 1000VDC | ≥100MΩ |
| Short-Time Overload | 10 times rated power, 5S | No visible damage |
| Load Life | Cyclic operation | >9000h |
| Damp Heat Test | 40℃±2℃, 90%-95%RH, 100h | △R≤±(1%R+0.05Ω) |
| Temperature Cycling | -55℃/55℃/155℃ cycling | △R≤±(2%R+0.05Ω) |
| Heat Resistance | 350℃/2h | No obvious damage |
| Temperature Coefficient | Rated load condition | <300 ppm/℃ |
| Performance Item | Test Condition | Requirement |
|---|---|---|
| Terminal Strength | 45N/30S | No looseness or damage |
| Vibration Resistance | 5-200Hz, 1g | No structural damage |
| Soldering Heat Resistance | 350±5℃, 3S | No visible damage |
| Solderability | 235±5℃, 5S | Solder coverage >95% |
Dufew provides customized braking resistor solutions according to inverter specifications, operating conditions, and installation requirements. Configurations can be adjusted for rated power, resistance value, voltage, enclosure dimensions, protection grade, installation structure, terminal arrangement, and resistor element type.
The same enclosure platform can accommodate different resistor elements, including corrugated, aluminum housed, and tubular types, allowing the configuration to be matched to the required power capacity, thermal conditions, and application environment.
Dufew Electric integrates resistor element assembly, enclosure fabrication, electrical testing, and final inspection within a standardized production process. Each stage is controlled to maintain consistent electrical performance, mechanical quality, and delivery reliability for customized industrial applications.
The manufacturing process is supported by a professional electrical component workshop, standardized assembly procedures, complete performance testing, customized production capability, and export-standard packaging. These capabilities allow Dufew to manage projects from resistor configuration through finished cabinet delivery.
Dufew selects packaging methods according to product dimensions, weight, and transportation requirements, using secure internal fixation and protective structures to reduce the risk of impact during handling. The packaging is suitable for international shipments as well as bulk orders and customized industrial projects.
| Comparison Item | Braking Resistor Box | Load Resistor / Individual Resistor |
|---|---|---|
| Application Purpose | Designed for inverter regenerative braking and DC bus voltage control | Mainly used for general load testing or independent applications |
| Energy Handling | Optimized for short-time high-power braking pulses | Usually designed for continuous power dissipation |
| System Integration | Complete assembly with enclosure and protection components | Requires additional installation and protection design |
| Temperature Protection | Built-in temperature monitoring and safety protection | Protection depends on external system design |
| Industrial Adaptability | Suitable for elevators, cranes, and heavy-duty drive systems | More suitable for standard testing environments |
Dufew Electric follows strict quality management procedures to ensure product reliability and consistency.
Quality control covers:
- Incoming material inspection
- Production process monitoring
- Electrical performance testing
- Final product inspection
Certificates and test reports are available according to customer requirements.
A braking resistor absorbs the regenerative energy generated when a motor decelerates or stops. It converts excess electrical energy into heat, helping prevent DC bus overvoltage faults and improving inverter reliability.
The standard protection level is IP20 or IP23. Higher protection levels can be customized according to installation conditions, such as outdoor environments or industrial areas with dust and moisture.
Yes. The enclosure structure can be configured with different resistor elements, including corrugated resistors, aluminum housed resistors, and tubular resistors, depending on the required application.
Yes. Multiple units can be connected in parallel when the rated power, resistance value, and installation conditions are properly matched to ensure balanced load sharing and reliable heat dissipation.
Dufew controls quality through material inspection, standardized manufacturing processes, electrical testing, and final inspection to ensure stable product performance for industrial applications.
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No. 364, Kangyang Road, Huangdai Town, Xiangcheng District, Suzhou City, Jiangsu Province, China
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