In fields like new energy vehicles and industrial automation, where strict requirements for power and stability apply, a resistor product that balances high heat dissipation, pulse resistance, and easy installation is often the key to ensuring the safe operation of equipment. The ASZ Series Aluminum Housed Resistors launched by Shenzhen ZENITHSUN Electronics, with its wide power range of 40W-800W, high stability, and adaptability to multiple scenarios, has become the “preferred solution” for new energy vehicle pre-charging, industrial control braking, and other scenarios. What core advantages does it possess? And what solutions can it provide for different industries?
What is the ASZ Series Aluminum Housed Resistor?
The ASZ Series Aluminum Housed Resistors are power resistor products developed by Shenzhen ZENITHSUN Electronics, covering two core models: ASZ4020/6030 and ASZ4026/6038. With a power range of 40W to 800W, the resistance tolerance can reach ±1% (Class F), ±2% (Class G), and ±5% (Class J), meeting the precise resistance requirements of different scenarios.
In terms of structure, the core competitiveness of this aluminum housed resistor stems from its “solid material and process design”: its core resistor element uses an insulating and high-temperature-resistant material as the framework, wound evenly with high-quality alloy wires, and enclosed in a shell made of high-grade industrial 6063 aluminum alloy. The 6063 aluminum alloy not only has high mechanical strength but also undergoes surface high-temperature anodization, which not only improves the appearance texture but also enhances heat dissipation efficiency. Meanwhile, the interior of the resistor is potted with high-insulation non-flammable electronic paste, tightly combining the aluminum shell with the resistor core into a stable entity, completely isolating the influence of external air, vibration, and dust. This is the key to its ability to maintain high stability in complex industrial environments.
Function of ASZ Series Aluminum Housed Resistors
As a high-power, high-stability resistor product, the core functions of the ASZ Series Aluminum Housed Resistors focus on “energy management and equipment protection”, especially excelling in high-power scenarios:
1. Power Loading and Energy Discharge: Precisely Controlling Current and Energy
In new energy vehicle pre-charging scenarios, the ASZ Series Aluminum Housed Resistors can act as “pre-charge resistors”, slowly charging the high-voltage capacitors when the vehicle starts, avoiding instantaneous high-current impacts on the on-board circuit and battery, and protecting core components from damage. In industrial control (such as frequency converters, elevators, and hoisting equipment), they can serve as “braking resistors”, converting excess electrical energy generated during equipment braking into heat and dissipating it quickly, preventing electrical energy backflow from impacting components like frequency converters and ensuring stable start-stop of equipment.
At the same time, they can also be used in scenarios such as loading, pulsing, discharging, starting, and buffering. For example, they act as “buffer resistors” in power supply systems to limit inrush current during startup; in energy storage equipment, they serve as “discharge resistors” to ensure safe release of residual power in energy storage units during maintenance, fully covering energy management needs.
2. Efficient Heat Dissipation: Solving the “Heat Generation Pain Point” in High-Power Scenarios
The “heat dissipation challenge” under high-power operation is a shortcoming of many resistor products, but the ASZ Series Aluminum Housed Resistors overcome this pain point through a “material + structure” dual design: the 6063 aluminum alloy shell itself has excellent thermal conductivity, and combined with the high-temperature anodization process, its heat dissipation efficiency is increased by more than 30% compared with ordinary metal shells. Additionally, the “tight structure” brought by the potting process allows heat to be quickly conducted from the resistor core to the shell, and then diffused into the air through the shell (it can also be used with heat dissipation devices to further improve heat dissipation efficiency).
According to the technical parameters of ZENITHSUN Electronics, the ASZ Series Aluminum Housed Resistors can be configured at 2-3 times the rated power when used at full load. This means that even under short-term high-power impacts, they can maintain stable operation through efficient heat dissipation without performance degradation or damage due to overheating.
3. Stable Adaptability: Ensuring Equipment Reliability in Complex Environments
Vibration, dust, and temperature fluctuations in industrial scenarios are often “invisible killers” of resistor products, but the “fully enclosed potting structure” of the ASZ Series Aluminum Housed Resistors solves this problem perfectly. The non-flammable electronic paste potting not only isolates external interference but also improves the vibration resistance of the resistors. Even in bumpy or harsh environments such as ships, railway systems, and military equipment, they can maintain stable resistance values and avoid equipment failures caused by fluctuations in resistor performance.
In addition, their wide temperature coefficient (+100PPM to +400PPM) ensures that the resistance change rate remains within a controllable range at temperatures from -40℃ to +155℃, adapting to diverse environments from cold outdoor areas to high-temperature workshops.
Advantages of ASZ Series Aluminum Housed Resistors
Compared with ordinary power resistors, the advantages of the ASZ Series Aluminum Housed Resistors can be summarized into three cores: “high stability, strong adaptability, and easy installation”:
1. High Stability and Durability: Adapting to Complex Working Conditions
The combination of an insulating high-temperature-resistant framework, alloy wire winding, 6063 aluminum shell, and non-flammable potting paste endows this resistor with “pulse resistance, impact resistance, and corrosion resistance” characteristics. It can operate stably for a long time in high-interference, high-power scenarios such as wind power generation, solar power generation, and welding equipment. It has high product consistency and a service life far exceeding that of ordinary carbon film or metal film resistors.
2. Flexible Customization: Meeting Diverse Needs
From lead terminal types and temperature switch configurations to waterproof grades, shell colors, and mounting hole sizes and distances, the ASZ Series Aluminum Housed Resistors support multi-dimensional customization. They can even be combined into resistor boxes or resistor cabinets according to customer needs—for example, customizing high-power resistor cabinets for large energy storage power stations and miniaturized resistor modules for elevator systems—eliminating the need for additional adaptation and modification by customers.
3. Easy Installation and Low Cost: Balancing Practicality and Economy
Despite its excellent performance, the ASZ Series Aluminum Housed Resistors still maintain an “economical” positioning. Compared with cement resistors or ceramic resistors of the same power, they have a more cost-effective advantage. At the same time, their standardized size design (e.g., ASZ4020/4026 models have a length of 90-185mm and width of 40mm; ASZ6030/6038 models have a length of 165-365mm and width of 60mm) and flexible lead terminal design make the installation process simple and efficient, reducing the equipment assembly cost for customers.
Applications of ASZ Series Aluminum Housed Resistors
With its multi-scenario adaptability, the ASZ Series Aluminum Housed Resistors have been widely used in new energy, industry, transportation, energy, and other fields.
- New Energy Field: Pre-charging of new energy vehicles, discharging/buffering of energy storage systems, and loading of solar inverters;
- Industrial Control Field: Braking of frequency converters, braking of elevators and hoisting equipment, power management of automation equipment, and energy control of welding equipment;
- Transportation and Energy Field: Marine power systems, railway traction systems, wind power converter, military and aviation equipment (scenarios with high stability requirements);
- Other Fields: Power supply equipment, lighting systems (current control), and medical equipment (low interference requirements).
From the “safe start” of new energy vehicles to the “stable braking” of industrial equipment, the ASZ Series Aluminum Housed Resistors, with their characteristics of “high stability, high heat dissipation, and high adaptability”, have become “reliable partners” for equipment in different industries. For enterprises pursuing equipment safety and long-term operation, this aluminum housed resistor, which balances performance and cost-effectiveness, is undoubtedly the preferred solution for meeting high-power resistor needs. If you are looking for a suitable resistor for pre-charging, braking, loading, and other scenarios, feel free to learn about the ASZ Series Aluminum Housed Resistors from ZENITHSUN Electronics and customize an exclusive resistor solution.