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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.
DUFEW Corrugated Resistor Box is a high-power resistor assembly that integrates multiple corrugated resistor elements through series and parallel connection methods and fixes them inside a professional enclosure. It is specially developed to overcome the power limitation of individual resistors and provide stable energy absorption performance for high-power electrical systems.
The resistor box supports a maximum power rating of 30KW, resistance values from 0.01Ω to 1KΩ, and resistance accuracy options of ±3%, ±5%, and ±10%. The internal structure includes a high-current terminal block and temperature protection switch, while the enclosure protection grade can be customized according to different application requirements.
As an experienced manufacturer and supplier in China, DUFEW provides customized solutions for braking systems, variable frequency drives, industrial automation equipment, elevators, cranes, rolling mills, and other applications requiring efficient energy dissipation.
The internal structure of the Corrugated Resistor Box consists of multiple corrugated resistor elements arranged through series and parallel circuits and mounted securely inside a specially designed enclosure. This modular configuration improves power capacity while maintaining stable electrical performance and convenient maintenance.
The enclosure is manufactured from aluminum-zinc coated steel sheet, which provides excellent corrosion resistance, mechanical strength, and heat dissipation capability. The integrated ventilation structure helps optimize airflow and maintain stable temperature during continuous operation.
A high-current terminal block is installed inside the resistor box to simplify external electrical connections. The built-in temperature protection switch automatically disconnects the circuit when the internal temperature exceeds the preset safety limit, preventing overheating damage.
According to customer requirements, DUFEW can provide optional cooling fans, independent resistor group control, and customized protection levels. The product is designed according to GB-5792 standard and is suitable for demanding industrial environments.
Example: CRB 10KW 13.6R J
| Code | Description |
|---|---|
| CRB | Corrugated Resistor Box / Braking Resistor Box |
| 10KW | Rated Power |
| 13.6R | Rated Resistance |
| J | Resistance Tolerance (K=10%, J=5%, H=3%) |
| Parameter | Specification |
|---|---|
| Power Range | 1KW-30KW |
| Working Voltage | ≤1200V |
| Resistance Range | 0.01Ω---1KΩ |
| Resistance Tolerance | ±3/±5/±10 |
| Protection Grade | IP20/IP23 |
| Temperature Coefficient | ≤300 ppm/℃ |
| Flame Retardant Grade | UL 94V-2 |
| Standard Compliance | GB-5792 |
DUFEW provides customized Corrugated Resistor Box solutions based on different industrial operating conditions. Customers can select suitable power ratings, resistance values, cooling methods, protection levels, and internal circuit configurations according to their system requirements.
The modular design allows multiple resistor units to be combined into different power levels, making the product suitable for applications with high braking energy, frequent acceleration and deceleration, and continuous duty operation.
Customization options include:
- Customized rated power
- Customized resistance value
- Multi-group resistor circuit design
- Additional cooling fan installation
- Customized enclosure structure
- OEM production according to customer drawings
The Corrugated Resistor Box absorbs regenerative energy generated during motor deceleration and helps prevent DC bus overvoltage faults.
Designed for frequent braking operations in cranes, hoisting equipment, and material handling systems.
Provides stable braking performance for high-power motors operating under continuous load conditions.
Suitable for elevator systems requiring frequent acceleration, deceleration, and energy consumption control.
Used as a reliable high-power load component for electrical testing and energy dissipation applications.
The DUFEW Corrugated Resistor Box adopts a modular internal resistor structure. Multiple resistor elements are divided into independent groups and connected through separate circuits, allowing easier maintenance and reducing replacement costs.
When a single resistor group fails, technicians only need to replace the damaged module instead of replacing the entire resistor box. This design significantly improves equipment availability and reduces long-term maintenance expenses.
Internal resistor elements are divided into separate circuits. A single damaged section can be replaced independently without affecting the operation of other resistor groups.
The front-mounted high-current terminal block provides centralized and organized wiring. Large power cables can be connected and disconnected easily during installation, inspection, and maintenance.
The standard temperature protection switch automatically disconnects the circuit when abnormal temperature conditions occur, preventing resistor damage caused by overheating during unattended operation.
The DUFEW Corrugated Resistor Box is specially designed for heavy-duty equipment requiring frequent braking, high energy absorption, and long continuous operation.
It is suitable for industrial applications such as rolling mills, port cranes, and heavy-duty elevators, where braking resistors need to withstand repeated energy discharge cycles.
Suitable for equipment with frequent energy feedback conditions, including rolling mills, port machinery, and heavy-load elevators. The cyclic service life can exceed 9000 hours under specified operating conditions.
For high-power applications or high-temperature environments, cooling fans can be installed to improve heat dissipation efficiency and maintain stable operation.
Uniform enclosure dimensions allow multiple resistor boxes to be installed in parallel, providing a neat layout solution for large testing systems and complete electrical control equipment.
The resistor element is manufactured from constantan or nickel-chromium alloy strips formed into a corrugated structure. This design reduces parasitic inductance and improves response performance, making it suitable for high-frequency pulse braking and demanding industrial applications.
The increased surface area of the corrugated strip enhances heat dissipation efficiency, while maintaining a temperature coefficient of ≤300 ppm/℃ for stable resistance performance during operation.
Key advantages include low-inductance characteristics, excellent thermal stability, efficient heat dissipation, and reliable performance under frequent pulse loading conditions.
The enclosure is constructed from aluminum-zinc coated steel sheet, providing strong corrosion resistance and oxidation protection for industrial environments. Precision bending, welding processes, and optimized ventilation channels improve both structural strength and airflow efficiency.
Key advantages include corrosion resistance, mechanical durability, improved thermal management, and adaptability to demanding working conditions.
High-temperature ceramic or mica supports are used to secure the corrugated resistor elements while providing electrical isolation between heating components and the enclosure. The insulation structure maintains reliable performance under thermal conditions up to 350℃.
Key advantages include high-temperature resistance, stable electrical insulation, enhanced safety, and long service life under continuous thermal stress.
The resistor box adopts a high-current copper busbar terminal structure designed for reliable connection in high-power applications. The multi-circuit wiring design helps organize cable connections, reduce heat generation, and improve electrical stability.
Key advantages include high current carrying capability, convenient installation, stable electrical connection, and suitability for large power systems.
Optional configurations include temperature protection switches and axial cooling fans. The temperature switch provides additional safety by disconnecting the circuit when abnormal temperature conditions occur, while forced air cooling helps reduce temperature rise and improve continuous operation capability in enclosed installations.
| Electrical Performance | Test Conditions | Performance |
|---|---|---|
| Dielectric Strength | 2500VAC/50Hz/60S | Leakage current ≤10mA |
| Insulation Resistance | 1000VDC | Insulation resistance ≥100MΩ |
| Short-Time Overload | 10 times rated power for 5S | No visible damage |
| Long-Term Load Life | Cyclic operation (Discharge 10S, Interval 90S) | More than 9000h |
| Steady-State Damp Heat | 40℃±2/90%-95%RH/100h | △R≤±（1%R+0.05Ω） |
| Rapid Temperature Change | -55℃, 55℃, 155℃ each for 15 minutes, 5 cycles | △R≤±（2%R+0.05Ω） |
| Heat Resistance | 350℃/2h | No obvious discoloration or damage |
| Temperature Coefficient | Comparison between rated load resistance and static resistance | Less than 300 ppm/℃ |
| Flame Retardancy | 10 times rated power for 5 minutes | Red glow but no flame |
| Mechanical Performance | Test Conditions | Performance |
|---|---|---|
| Terminal Strength | 45N/30S | No loosening or visible damage |
| Vibration Resistance | 5-200Hz, 1g, 98m/S² | No visible structural damage |
| Soldering Heat Resistance | Lead terminal immersed in 350±5℃ solder for 3S | △R≤±（1%R+0.05Ω） No visible external damage, clear marking |
| Solderability | Terminal immersed in 235±5℃ solder for 5S | Solder coverage on terminal surface ≥95% |
Selecting a suitable braking resistor solution is important for improving system stability, safety, and maintenance efficiency. Compared with individual aluminum housed resistors, tubular resistors, or standalone resistor elements, DUFEW provides a more integrated design with improved protection, thermal management, and easier installation for industrial power applications.
| Comparison Dimension | Corrugated Resistor Box | Traditional Single Aluminum Housing / Tubular / Independent Resistor |
|---|---|---|
| Power Handling Capability | Multiple corrugated resistor elements can be combined through series and parallel circuits, allowing a single enclosure to achieve up to 30KW power capacity while providing unified protection and connection management. | Individual resistors usually have limited power capability. Multiple units require additional combination, wiring, and protection structures, increasing installation complexity. |
| High-Frequency Performance | The corrugated alloy strip structure provides low-inductance characteristics, helping reduce voltage spikes, electromagnetic interference, and instability during high-frequency braking operations. | Traditional resistor structures may generate higher parasitic inductance, which can affect performance in applications with rapid switching or pulse braking conditions. |
| Protection and Safety | The integrated metal enclosure protects internal heating elements from dust, moisture, and accidental contact. Protection grades can be customized according to application requirements. | Exposed resistor elements provide limited environmental protection and may require additional safety covers or protection components. |
| Thermal Management | The internal airflow structure and optimized resistor arrangement improve heat distribution and reduce local temperature accumulation during continuous operation. | Multiple independent resistors installed together may lack effective airflow organization, increasing the risk of uneven heating and accelerated aging. |
| Maintenance Convenience | The modular internal structure allows easier inspection and replacement. Integrated terminals and temperature protection components simplify maintenance procedures. | Separate resistor installations usually require more complicated wiring and component replacement processes without centralized protection and monitoring. |
A: This solution is suitable when the application requires higher power capacity, integrated enclosure protection, or more convenient maintenance than a single resistor can provide. It is commonly applied in variable frequency drive systems, cranes, elevators, rolling mills, and other industrial equipment with frequent braking requirements.
A: The built-in temperature protection switch monitors operating temperature continuously. When the temperature exceeds the preset safety limit, the protection device disconnects the circuit to reduce overheating risks and protect the resistor system.
A: Yes. For applications involving high power output, frequent braking cycles, or limited ventilation conditions, an optional cooling fan system can be installed to improve heat dissipation and maintain stable operation.
A: Yes. The internal resistor elements can be configured into multiple independent groups according to application requirements. This allows flexible load adjustment, easier fault isolation, and improved system reliability.
A: Standard configurations support power ratings from 1KW to 30KW. For applications requiring different power levels, DUFEW can develop customized solutions based on operating conditions and technical specifications.
A: Resistance values can be customized according to system requirements. Standard options include different resistance ranges and tolerances of ±3%, ±5%, and ±10%, depending on the electrical application.
A: It is widely used in industrial drive and energy control applications, including variable frequency drives, cranes, port machinery, elevators, rolling mills, automation equipment, and electrical testing systems. It is especially suitable for applications requiring repeated braking, energy dissipation, and stable thermal performance.
A: Yes. DUFEW supports customized designs according to customer requirements, including power rating, resistance value, enclosure structure, protection level, cooling method, and internal circuit configuration. Customers can provide application details or technical drawings, and DUFEW engineers will develop a suitable solution based on actual operating conditions.
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