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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 Inverter Aluminum Clad Resistor is specially designed for variable frequency drive (VFD) braking systems, servo drives, and industrial motor control applications requiring reliable regenerative energy absorption.
During motor deceleration, lifting, or rapid stopping operations, the motor generates regenerative energy that flows back to the inverter DC bus. If this energy cannot be effectively consumed, excessive voltage buildup may trigger inverter overvoltage faults or damage power components.
DUFEW inverter braking resistors convert regenerated electrical energy into heat energy through a high-performance aluminum clad resistor structure, helping maintain stable inverter operation and improve system safety.
Featuring a durable aluminum alloy housing, high insulation encapsulation technology, and optimized thermal management design, DUFEW provides reliable braking resistor solutions for industrial automation manufacturers, inverter suppliers, and equipment builders worldwide.
Available in 50W-6KW power ratings, 0.01Ω-120kΩ resistance values, and customizable specifications to match different inverter braking requirements.
Unlike general-purpose resistors, inverter braking resistors are required to withstand repeated short-duration high-power energy pulses during braking cycles.
DUFEW Inverter Aluminum Clad Resistor is engineered to handle:
- Sudden regenerative energy release
- Frequent acceleration and deceleration cycles
- Short-time overload conditions
- Dynamic braking requirements
By safely dissipating excess energy, it helps:
- Prevent DC bus overvoltage
- Protect inverter modules
- Improve braking response
- Increase equipment reliability
| Feature | Benefit |
|---|---|
| Designed for VFD braking applications | Matches variable frequency drive energy dissipation requirements |
| High pulse energy absorption capability | Handles repeated braking and regeneration cycles |
| Aluminum alloy heat dissipation housing | Quickly transfers heat during operation |
| Fully enclosed encapsulated structure | Protects against dust, moisture, and vibration |
| Standard mounting hole design | Easy installation and replacement |
| Multiple terminal options | Supports different wiring requirements |
| Custom resistance and power options | Matches different inverter specifications |
The resistor element is built with high-temperature insulating materials and wound with premium Nickel-Chromium (Ni-Cr) or Copper-Nickel (Cu-Ni) alloy resistance wire. After mica insulation isolation, the assembly is filled with flame-retardant thermal compound and sealed inside an aluminum alloy housing.
This integrated structure improves mechanical strength, vibration resistance, heat transfer efficiency, and long-term operating reliability in industrial braking applications.
The internal structure uses quartz filling combined with special bonding compounds to enhance thermal conductivity. Compared with traditional air insulation, this design transfers heat more efficiently from the resistor element to the aluminum housing.
Together with the external heat dissipation grooves, the thermal design helps maintain stable braking performance, improve temperature balance, and extend service life under repeated load conditions.
DUFEW supports different connection options, including stainless steel terminals and high-temperature lead wires, to meet various installation requirements. The integrated mounting holes simplify installation inside inverter cabinets and industrial control systems.
Selecting the correct resistor requires consideration of inverter parameters, braking conditions, and installation environment.
| Selection Factor | Consideration |
|---|---|
| Resistance Value | Must match the inverter manufacturer's recommended braking resistance range |
| Power Rating | Selected according to braking frequency and required energy absorption capacity |
| Motor Power | Higher motor capacity generally requires stronger braking capability |
| Duty Cycle | Frequent braking operations require higher thermal capacity |
| Installation Environment | Ventilation conditions and cabinet cooling design should be evaluated |
Incorrect resistor selection may result in excessive braking current, insufficient braking torque, overheating, or inverter protection alarms. DUFEW recommends selecting suitable resistance values based on inverter specifications and actual operating requirements.
| Application | Function |
|---|---|
| Variable Frequency Drives (VFD) | Absorbs regenerative energy during motor braking |
| Servo Drive Systems | Handles servo motor deceleration energy |
| Elevators | Controls energy generated during lowering and braking |
| Cranes and Hoisting Equipment | Supports frequent start-stop operation |
| Industrial Automation Equipment | Provides dynamic braking protection |
| Electronic Load Testing | Acts as a high-power resistive load |
| Renewable Energy Equipment | Energy discharge and protection circuits |
| Parameter | Specification |
|---|---|
| Product Type | Inverter Aluminum Clad Resistor |
| Application | Dynamic Braking / Regenerative Energy Dissipation |
| Power Range | 50W -- 6KW |
| Resistance Range | 0.01Ω -- 120kΩ |
| Operating Voltage | ≤1200V |
| Resistance Tolerance | ±3%, ±5%, ±10% |
| Resistance Wire Material | Nickel-Chromium / Copper-Nickel Alloy |
| Housing Material | Aluminum Alloy |
| Insulation Material | High Temperature Flame Retardant Compound |
| Temperature Coefficient | ≤300 ppm/℃ |
| Protection Grade | IP00 |
| 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 /5s | No visible damage |
| Long-Term Load Life | Cyclic discharge operation | >9000h |
| Humidity Resistance | 40℃±2℃ /90%-95%RH /100h | ΔR≤±(1%R+0.05Ω) |
| Temperature Cycling | -55℃ to 155℃ cycles | Stable performance |
| Heat Resistance | 350℃ /2h | No obvious damage |
| Flame Test | 10 times rated power | No combustion |
| Comparison | DUFEW Inverter Aluminum Clad Resistor | General Power Resistor |
|---|---|---|
| Application Purpose | Designed for regenerative braking energy absorption | Designed for ordinary load applications |
| Energy Handling | Supports short-time high-energy pulses | Mainly suitable for stable loads |
| Motor Control Compatibility | Matches VFD and servo braking systems | No inverter-specific design |
| Overvoltage Protection | Helps prevent DC bus overvoltage faults | Limited protection capability |
| Thermal Design | Optimized for repeated braking cycles | May overheat under frequent pulses |
| Installation | Designed for control cabinet integration | General-purpose installation |
Before installation, verify the inverter model, recommended resistance range, required braking power, and duty cycle to ensure the resistor matches the system requirements.
Check the aluminum housing, terminals, encapsulation condition, and mounting structure before installation to confirm the resistor is free from damage and ready for operation.
Proper heat dissipation is essential for reliable braking operation. Vertical installation is recommended to improve airflow, while sufficient spacing should be maintained between resistors. For enclosed cabinets, additional forced ventilation may be required according to operating conditions.
Use heat-resistant cables, ensure secure terminal connections, and keep the wiring distance between the inverter and resistor as short as practical to improve connection reliability.
After installation, check the resistance value, monitor the surface temperature during operation, and verify braking performance to ensure the system functions correctly.
DUFEW supports customized inverter braking resistor solutions including:
| Custom Item | Available Options |
|---|---|
| Resistance Value | Custom resistance matching inverter requirements |
| Power Rating | 50W-6KW |
| Housing Size | Customized dimensions |
| Terminal Type | Stainless terminals / lead wires |
| Protection Components | Optional thermal protection |
| Application Design | Customized according to braking conditions |
An inverter aluminum clad resistor absorbs regenerative energy generated during motor braking and converts it into heat energy, preventing DC bus overvoltage and protecting the inverter system.
The resistance value should follow the inverter manufacturer's recommended range. A value that is too low may cause excessive current, while a value that is too high may reduce braking performance.
Yes. DUFEW inverter braking resistors are suitable for servo systems, especially applications requiring rapid deceleration and repeated braking cycles.
Yes. DUFEW supports adding thermal switches or temperature protection components for applications requiring additional safety monitoring.
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No. 364, Kangyang Road, Huangdai Town, Xiangcheng District, Suzhou City, Jiangsu Province, China
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