Power Resistors

Design Resources

Engineering design tools

electrical resistor design software

ANSYS Finite Element Analysis simulation being carried out in our Leicester design office.

All Cressall’s products are designed, engineered and manufactured at our sites in Leicester and Dereham using the very latest computer-aided design tools – we have 14 full-time qualified engineers, 10 seats of Autodesk Inventor for 3D modelling and design, ANSYS for thermal, structural, seismic and fluid flow analysis and Radan as the interface with our metalworking machines.

These resources plus a library of more than forty years of proven designs and test data enable us to respond quickly and accurately to new product requests. Designs are validated initially using finite element models derived from past testing and then definitively by full-scale testing to our customers’ requirements.

ANSYS Mesh design

Modelling of air velocity generated by natural convection heat transfer from a resistor element running at full power. This analysis enables the distribution of the resistor elements to be optimised for a high power load bank design.

transmission system test

FE analysis of pressure excepted on the surfaces on a stacked resistor design under severe winding speeds. In this case 55m/s (123mph) for use on an HVDC transmission system in Scotland. Based on this analysis the structural strength requirement could be accurately defined.

EV2 with manifolds_013_325

Simulation of water velocity distribution within an EV resistor design. The images generated by this analysis enabled the link between empirical results and fluid dynamics theory to be linked together. The resulting images give a very good visual representation of the system in action.

EV2 with manifolds325

Simulating current density within a resistor can help to identify and quantify hot spots in the element. In this case the shape of the element has been varied to include a large radius around the hairpin bends in the element. The red parts of the image show that these areas have the highest current density. Through an iterative process the peak current density has been reduced to an acceptable level.