Powering the Future: The Crucial Role of Resistors in Electric Vehicle Charging
It’s
no secret. When it comes to vehicles, the future is electric. What once seemed like an elusive luxury is now becoming the standard in
automotive manufacturing. Many automakers are looking to join the likes
of Tesla and have committed to developing more cost-effective EV options
and increasing the size of their EV fleet. For example, Ford has
announced its initiative to produce more than two million electric
vehicles by 2026 and Volkswagen has invested $193 billion into their
plans to support the goal of making every fifth vehicle sold electric by
2025.
With the rise of electric vehicles on the roads comes the need for more charging infrastructure. In 2022, the United States introduced a nearly $5 billion investment into EV charging stations that will be put into place over the next five years. However, building the charging infrastructure is only part of the challenge – reducing the amount of time to fully charge is the other.
There are currently three charger types and speeds:
Level
1 chargers are commonly found in residential areas with a 120-volt AC
outlet. For Battery Electric Vehicles (BEV), it can take 40-50+ hours to
charge from empty to 80%. Plug-in Hybrid Electric Vehicle (PHEV) can
take 5-6 hours.
Level 2 offers higher-rate AC charging through 240V in residential applications or 208V in commercial applications. This is the common equipment for homes and public charging stations.
Direct Current Fast Charging (DCFC) offers rapid charging at heavy-traffic stations such as grocery stores and gas stations, with 400 V to 1000 V DC, and 20 minutes to one hour for a full BEV Charge.
No matter the charging speed, a critical element of the charging process is regulating the heat generated due to the battery charging current. Failure to regulate the heat can cause the battery to overheat and potentially result in catastrophic failure or fire. This is where Resistors come in.
Current Sense Resistors are a reliable and cost-effective solution for current control, which in turn controls the generation of heat in the vehicle battery while charging. One manufacturer, TT Electronics, has a wide range of current sense resistors that can be utilized in battery management systems.
“It is, of course, critical to have the right resistor technology, rating, and value,” said Stephen Oxley of TT Electronics. “But what is sometimes less understood is the need to consider secondary factors – like reliability, surge performance and consistency, and safety in the event of excessive overload.”
As accessibility to EV charging has increased, charging stations have begun to pop up everywhere, including gas stations and popular destinations on major highways, which are often exposed to the elements. This is where Wire wound resistors come in.
“Wire wound resistors in ceramic cases, like TT Electronics’ AEC-Q200 qualified WPRT Series, were once used only in industrial applications,” said Oxley. “But these resistors have found a new lease on life in battery management systems for electric vehicles due to their high surge and overload tolerance, safe and flameproof construction, and high reliability.”
Wire wound resistors offer critical transient protection from hazardous surges caused by lightning strikes, where up to 14,000-volt surges can occur. According to Oxley, TT Electronics’ axial leaded power wire wound resistors have been developed to meet these demanding specifications.
“In addition to standard products, TT Electronics has the unique flexibility to provide custom solutions that meet the specific requirements of applications,” said Oxley. “With the EV landscape rapidly evolving, it can be tricky for designers to select the right resistor for their applications, something with which TT Electronics can certainly help.”
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Resistors for Battery Management Systems
With an industry-tested catalog of advanced resistors, TT Electronics is prepared to take your BMS to the next level. EBW8518 resistors have a continuous power rating of 36W with overload protection up to 180W for five-second surges. LRMAP3920/LRMAP5930 power resistors are suitable for fast and high surges (up to 50W for five-second overloads).LRMA/ULR resistors have proven instrumental in consumer markets.WPRT and PWHW resistors are suitable for an extremely broad range of applications.WDBR resistors are the element of choice when it comes to compact pulse withstanding solutions.
TT Electronics （TT）电阻器选型指南
目录- Technology and Product Selector Guides Current Sense Resistors High Value/Voltage Resistors Surge/Pulse Resistors High Power Resistors Precision/Fusible Resistors High Reliability Resistors Temperature Sense & Thermal Management Resistors Zero-Ohm Jumper & General Purpose Resistors Colour Code for Band-marked Resistors
型号- BCN168SB,WH SERIES,T 2010,WP25S,WMO7S,BCN168RB,0612X,BCN,WP5SZI,WHS-UL,WIN SERIES,RCP,SQM5,SQM3,SQM2,EBW5216,N 0815,LRF SERIES,SQM7,4507,LRCS,4500,WMO5S,4501,4502,4503,4504,VRW37,4505,4506,RHVD08,RC70P,T0603,WRM SERIES,HDSC,CR,LVC SERIES,VRW25,DIV23 SERIES,ULW SERIES,RHVD15,LRMAPXXXX SERIES,4530,GHVC SERIES,ULR3N,4531,WDBR-UL,TJC,RHVD10,RC65,WMO3S,BPR50,WH10,ULR,EMC,LCS SERIES,ULW,WP-SZI SERIES,WHPC,PCF,WMO2S,RC55,4532,4533,4534,4535,4536,4537,PCR,HPDC SERIES,OAR,SQP SERIES,WPYP10,ULR1S,BCN10,WSHR,ULR25,WRM,1900 SERIES,W20,WMO1S,W22,W21,T0805,W24,W23,SQP7,SQP5,ULR2N,BPR30,SQP2,SQP3,SOT143 SERIES,RC70,LR SERIES,WSM,HVC,W31,W30,HVD,WHS2,WHS3,WHS5,W20 SERIES,WH25,WHS7,WP3SZI,BPC3,RC65P,HVP,WH50,LHVC,HR,PFC,WMO-S SERIES,VRW,MFP1,MFP2,BPR10,WA84F,EBW SERIES,MF-S,WP-SZI,BPC7,BPC5,HVP SERIES,MFC SERIES,WSM2,WSMHP,WSM3,GHVC2512,MF1/2S,WCM SERIES,BPC10,LOB-5,ULR15S,LOB-3,MFR5,LRF3W SERIES,MFR3,MFR4,HVD08,RHVD10A,WH100,RC SERIES,VRW SERIES,SOT,RC55P,WSMHP25,HVD15,LR,WSMHP20,HVD12,1020X,DIV23,SPP,WMHP35,DSC,0508X,WRM-HP SERIES,WP-S SERIES,MF2S,LOB SERIES,MFR SERIES,HVD20,WHS10,WH200,WMHP50,SQM,PFC-HT,LRZ SERIES,SQP,BPC,LRMA,WSMHP SERIES,OARS-XP SERIES,LCS,MF1S,EMC SERIES,PR SERIES,BPR,WMHP20,N 0612,MFC,HVD30,RHVD15A,PCFH,T43,OARS-XP,T44,MFP,MFR,PCFP,T48,WCR SERIES,WA84F SERIES,WSMHP35,4530 SERIES,WH300,T0402,APC,HPWC,MF3S,VRW68,PR,WPYP SERIES,LRCS SERIES,OAR-5,OAR-1,OAR-3,1908,RC,PCR SERIES,RHVD SERIES,PCF SERIES,WHS5UL,1906,1905,1900,N 1225,BCN SERIES,PWC SERIES,1600 SERIES,LRF3W,ASC,WHPC SERIES,MFP SERIES,HTCR,PWP08,RCP SERIES,CAR SERIES,APC SERIES,WPYP8,P4026,PR5,PR4,TJC SERIES,WMHP,WP-S,SQM SERIES,SPP SERIES,PWP04,PWP06,OARS1,GHVC1206,T1206,OARS SERIES,HVP08,HVP06,TFHP SERIES,HVP04,WHS-UL SERIES,WRM-HV SERIES,PTS SERIES,HVD SERIES,M 2512,WSM SERIES,P 3920,WMO1/2S,WHS SERIES,SC3 SERIES,HVP15,ULR SERIES,HVP10,SPP-1,T 2512,LHVC SERIES,SPP-3,PTS,SPP-2,ULR2,ULR1,WH,WP2S,BPR SERIES,EMC2,WDBR1/2,ULR5,TFHP,HVP20,ULR3,M 1206,WL4 SERIES,BPR7,0207HP,BPR5,1602,BPR3,1601,SP20F SERIES,1600,WP1S,WPRT,WRM-HV,GCR,1609,1608,1607,1606,1605,SP20F,1604,1603,WRM-HP,WCM,WMHP SERIES,WCR,BPC SERIES,PFC-D,BCN164A,WP4S,WDBR5,WDBR SERIE,WDBR7,WDBR2,CAR7,PWC,WDBR1,CAR6,LOB,CAR5,WDBR3,PWP,P 2512,WP3S,BCN164AB,WPRT10,WPRT15,M 0805,P2817,OARSXP,RHVD,P 2726,WMO-S,WPRT20,EBW,3810,3811,WP2SZI,3812,CR SERIES,S0M10,DSC SERIES,WMHP100,GHVC,4800 SERIES,WPRT30,WP5S,HTCR SERIES,LRF,WH5,LRMA SERIES,P 5930,4804,4805,WPRT40,LRZ,GHVC2010,GCR SERIES,WPYP,PWP10,4800,PWP15,4802,WHS,HPDC,EBW8518,MF-S SERIES,OAR SERIES,PWP SERIES,4500 SERIES,ULW5,ULW4,ULW3,ASC SERIES,WPRT50,CAR,ULW2,OARS,PWP20,WHS3UL,W30 SERIES,4812,WIN,SQP20,SQM10A,LRMAPXXXX,3810 SERIES,WPRT SERIES,SOT143,HR SERIES,HVC SERIES,SQP15,SC3,SQP10,WDBR,WHS2UL,LVC,PFC-D SERIES,4832,WL4
TT Electronics Welwyn电阻选型表
TT Electronics Welwyn电阻选型，包括精密电阻、金属合金功率电阻、电流检测电阻、MELF电阻、线绕高浪涌电阻、通用表面安装电阻等，提供多参数选择，最小尺寸达0204，最小电阻值达0.2mΩ，公差范围±0.01%~±10%
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产品型号
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品类
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Size
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Value(mΩ、Ω)
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Tolerance(%)
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HR0603F-100MJI
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High Value Surface Mounted Resistors
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0603
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100MΩ
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±5%
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选型表 - TT Electronics 立即选型
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电流检测电阻器.应用说明
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TT Electronics EBW5216 Busbar Shunt Resistors for High Current Measurements in The Hundreds of Amps Range
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TT Electronics Resistors/Divider选型表
覆盖多种电阻以及高压平面分压器，分压器最小功率可达0.75W，TCR参数值有25ppm/℃、100ppm/℃，电阻最小功率可达0.063W，多阻值选择，最小公差0.01%
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产品型号
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品类
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Description
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Series
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Approval
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Power（W）
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LEV（V、kV）
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Resistance（Ω、kΩ、MΩ、GΩ、TΩ）
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Tolerance
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TCR（ppm/°C）
|
|
3810
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resistor
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Ultra-high value precision resistor
|
3810
|
None
|
0W
|
500V
|
100MΩ - 1TΩ
|
10%
|
500ppm/°C
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选型表 - TT Electronics 立即选型
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品类：Wirewound Power Radial Terminal Resistors
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品类：Low Resistance Metal Alloy Resistors
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