Liquid-cooled resistors for EV regenerative braking

20 June 2011

Cressall Resistors has developed a new range of liquid cooled resistors for the braking systems of hybrid and all-electric vehicles. The new range, dubbed the EV series, converts excess electricity that is not needed for recharging the vehicle’s battery into heat that can be dissipated safely. They make genuine regenerative braking in electric cars a possibility by providing a method to dissipate excess braking energy as heat, via the water system.

Compact and light enough for use in an electric car, Cressall’s EV series uses a system that encapsulates and totally separates the resistor elements from the coolant. The construction also achieves maximum thermal conductivity and maximum electrical insulation.

The simple modular construction means these resistors can be combined to handle any power inputs from 10kW upwards and voltages from 12V to 6kV. The coolant pressure is up to three bar and the coolant liquid can be water or water glycol.

The new EV range has been extensively vibration tested and has no ambient temperature limits. Furthermore, the unit’s simple design means that it can be mounted wherever appropriate in the vehicle’s coolant system.