INSTRUMENTATION • ELECTRONICS
cooling system and make adjustments to refine a design. Furthermore, by experimenting with different set-
ups, design engineers can identify the best solution and maximise the power rating that can be assigned to the resistor – all using digital tools. The EV2 water-cooled resistor has a very high
power density that enables Cressall to offer a compact solution where water cooling is a preferred option. An accurate design aimed at streamlining and reducing all possible pressure drops is therefore crucial to enable customers to use smaller pumps and saving energy on the long run. Thus CFD plays an important role in the design of water-cooled resistors such as the EV2. Recently, Cressall was asked to reduce the pressure
drop in one of the systems where an EV2 water-cooled resistor was installed. In particular, the customer was limited on the amount of pressure available from the pumping system in such a way that the minimum flow rate needed to cool down the EV2 modules could not be reached. In this case, Cressall was able to replicate accurately the bottleneck in the system and quickly identify the necessary improvements. The firm designed a new assembly to fit these
customer requirements. The design went directly into production following a simple proving test without time-consuming iterative physical testing. The revised product was delivered in-line with the customer’s maintenance schedule.
The applications of CFD are almost endless, but
the bottom line is that the software enables designers to pinpoint specific performance of new products and improvements to established designs with confidence. It allows suppliers to meet the bespoke requirements of customers, making their products more precise and reliable, while also minimising design and test costs for clients. Just like the Mini, the proof of good design is
its ability to withstand the test of time. Using CAE enables Cresall to create bespoke, reliable products, refining the classic design of the electrical resistor and bringing it into the era of smart manufacturing. l
Experimenting with digital tools allows design engineers to identify the best solution and maximise the power rating that can be assigned to a resistor
Damiano Natali is R&D engineer at Cressall Resistors.
www.cressall.com
www.engineerlive.com
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