English
We offer a comprehensive portfolio including resistors, braking units, reactors, power filters, and transformers, with full customization options to meet diverse application requirements.
DUFEW Custom-Shaped Aluminum Clad Resistor is an engineered solution developed for industrial equipment requiring special installation dimensions, unique mounting structures, or customized lead directions.
Unlike standard aluminum clad resistors with fixed dimensions, this customized power resistor can be manufactured according to your actual equipment layout, including housing shape, mounting holes, terminal position, and wire outlet direction.
With power ratings from 50W to 6KW, resistance values from 0.01Ω to 120kΩ, and tolerance options of ±3%, ±5%, and ±10%, DUFEW provides flexible OEM resistor solutions for automation systems, motor control equipment, transportation systems, and special industrial applications.
By matching the resistor design to the existing installation space, customers can avoid cabinet redesign, reduce modification costs, and simplify equipment integration.
Standard resistors are designed for standard equipment layouts. However, many industrial machines, special vehicles, and customized control systems have limited internal space or irregular mounting positions.
DUFEW develops customized aluminum clad resistors to solve these challenges.
| Feature | Customer Benefit |
|---|---|
| Custom housing geometry | Fits irregular equipment spaces without structural modification |
| Adjustable mounting holes | Direct installation without additional brackets |
| Flexible lead outlet direction | Avoids wiring interference inside control cabinets |
| Fully sealed aluminum construction | Protects resistance elements from dust, moisture, and vibration |
| Optimized thermal filling technology | Ensures uniform heat transfer and prevents local overheating |
| OEM engineering support | Provides customized solutions from prototype to mass production |
DUFEW provides customized aluminum housing designs based on customer drawings, installation requirements, and equipment layout conditions. The housing structure can be adapted for complex installation environments, including L-shaped configurations, offset structures, multi-angle designs, special cut-out shapes, and customized mounting bases.
This flexible design approach allows the resistor to be directly integrated into compact equipment spaces or systems with limited installation areas, reducing additional modification work during assembly.
The mounting structure can be modified according to specific equipment requirements, including hole spacing, countersunk depth, mounting ear quantity, and bracket angles.
By optimizing the mounting interface during production, DUFEW helps customers avoid additional adapters and achieve faster, more reliable installation.
The resistor element is manufactured with high-quality alloy resistance wire precisely wound on a high-temperature insulating core. After mica insulation isolation, the assembly is filled with quartz sand and special thermal bonding materials inside the aluminum housing to improve overall stability.
The encapsulation structure provides:
- Improved thermal conductivity compared with air insulation
- Stable heat transfer performance
- Enhanced electrical insulation capability
- Reduced risk of localized overheating
To meet different installation requirements, DUFEW supports multiple terminal and lead configurations, including stainless steel terminals, high-temperature lead wires, side outlet designs, and angled outlet structures.
These customized connection options help avoid interference with surrounding components and provide greater flexibility for system integration.
| Design Feature | Engineering Advantage |
|---|---|
| Custom-shaped aluminum shell | Matches special equipment installation environments |
| Quartz sand thermal filling | Improves heat dissipation efficiency |
| Alloy wire wound element | Provides stable resistance performance |
| Fully enclosed construction | Enhances dust and moisture protection |
| Aluminum heat dissipation body | Quickly transfers internal heat |
| Customized outlet direction | Simplifies electrical connection |
| Parameter | Specification |
|---|---|
| Product Type | Custom-Shaped Aluminum Clad Resistor |
| Technology | Wirewound Power Resistor |
| Power Rating | 50W -- 6KW |
| Resistance Range | 0.01Ω -- 120kΩ |
| Operating Voltage | ≤1200V |
| Resistance Tolerance | ±3%, ±5%, ±10% |
| Core Material | High Temperature Insulation Material |
| Resistance Wire | Premium Alloy Resistance Wire |
| Housing Material | Aluminum Alloy |
| Filling Material | Quartz Sand Thermal Compound |
| Temperature Coefficient | ≤300 ppm/℃ |
| Insulation Resistance | ≥100MΩ |
| Dielectric Strength | 2500VAC / 60s |
| Flame Rating | UL94V-2 |
| Standard | GB-5792 |
| Test Item | Test Condition | Performance |
|---|---|---|
| Dielectric Strength | 2500VAC / 50Hz / 60s | Leakage current ≤10mA |
| Insulation Resistance | 1000VDC | ≥100MΩ |
| Short Overload | 10 times rated power for 5s | No visible damage |
| Long-Term Load Life | Cyclic operation test | >9000h |
| Humidity Resistance | 40℃±2℃ / 90%-95%RH /100h | ΔR≤±(1%R+0.05Ω) |
| Temperature Cycling | -55℃ / 55℃ /155℃ cycles | Stable performance |
| Heat Resistance | 350℃ / 2h | No obvious damage |
| Flame Resistance | 10 times rated power | No combustion |
| Industry | Application |
|---|---|
| Industrial Automation | Customized braking and protection circuits |
| Servo Systems | Energy absorption and dynamic braking |
| Electric Vehicles | Space-limited power control systems |
| Special Vehicles | Customized electrical layouts |
| Testing Equipment | Load simulation systems |
| Renewable Energy | Energy discharge applications |
| Elevators & Cranes | Motor braking systems |
| Marine Equipment | Compact electrical control systems |
The customization process begins with a detailed review of customer requirements, including installation dimensions, mounting position, power rating, resistance value, and lead direction. These specifications help define the basic design requirements for the resistor structure.
Based on the application requirements, DUFEW engineers develop the suitable structure by evaluating housing design, heat dissipation performance, terminal configuration, and internal filling technology to ensure reliable integration with the customer's equipment.
After design confirmation, each resistor is manufactured through standardized production procedures and undergoes electrical and mechanical testing to verify performance, safety, and reliability before shipment.
| Comparison | Customized Solution | Standard Aluminum Clad Resistor |
|---|---|---|
| Housing Design | Flexible housing structures developed according to equipment requirements | Fixed rectangular housing design |
| Installation Compatibility | Can be integrated into irregular or limited installation spaces | Requires standard mounting conditions |
| Mounting Configuration | Mounting holes and brackets can be adjusted based on equipment layout | Fixed mounting dimensions |
| Terminal Arrangement | Multiple terminal and lead directions available | Standard terminal configuration |
| Equipment Integration | Reduces additional modification work during installation | May require adjustments to existing equipment structures |
| Application Range | Suitable for special machines and customized industrial equipment | Suitable for general industrial applications |
A customized solution is recommended when equipment has limited installation space, irregular mounting positions, or special connection requirements. It allows the resistor to fit existing system designs without major structural changes.
No. DUFEW uses optimized internal filling and thermal transfer structures to maintain uniform heat distribution and reduce the risk of localized overheating during operation.
DUFEW supports customization based on application requirements, including:
- Housing shape
- Mounting dimensions
- Power rating
- Resistance value
- Terminal type
- Lead direction
- Installation structure
Standard models are suitable for common installation environments, while customized designs provide greater flexibility for equipment with special space limitations, mounting requirements, or wiring layouts.
Address
No. 364, Kangyang Road, Huangdai Town, Xiangcheng District, Suzhou City, Jiangsu Province, China
Tel
