Discharge Resistors – Safety and efficiency for electric mobility

High-voltage systems are essential in electric vehicles, but they also pose risks. Discharge resistors play a key role in safely and efficiently dissipating energy and protecting people and animals in the event of a fault.
But what makes a good resistor, and how can it be best integrated? In this article, we highlight best practices for selecting and applying these essential components.
 

The challenges: What Makes a Good Discharge Resistor?

High-voltage systems in electric vehicles place high demands on the components used. Discharge resistors must safely dissipate the constant reduction of energy in the HV DC link to ensure discharge in the parking situation. The following factors are critical

• Thermal stability: The resistors must operate consistently and reliably even under high loads.
• Compact design: Space-saving solutions are required to make the most of the limited space available in vehicles.
• Durability: They must perform reliably under extreme conditions such as thermal and vibration shock. They must also have a long service life - the life of a car.

Best Practices for Discharge Resistor Selection and Application

The selection and integration of discharge resistors must be carefully matched to the specific requirements of the high-voltage system and installation conditions.
Here are the key best practices:

• Material selection and design: High-quality metal film resistors offer an optimal combination of thermal stability and energy efficiency. Their compact design makes them easy to integrate into tight spaces. They are also well suited for high voltages.
• Drive inverter integration: Strategic positioning can reduce thermal stress and increase performance. Optimized discharge strategies, such as constant-power discharge, further reduce the size of the discharge resistor.
• Quality Control: Various tests under realistic operating conditions guarantee the reliability and safety of the components. Miba uses state-of-the-art testing methods to ensure compliance with the strictest automotive standards.

What makes Miba Discharge Resistors unique?

More than 48 years of experience in a wide range of markets and applications pays off with resistance know-how. Miba offers a unique combination of technology, quality and adaptability in the development of discharge resistors.

The use of high-performance metal film resistors ensures exceptional thermal stability and robustness, even under extreme conditions.

At the same time, the compact design, which has been specially developed for integration into modern vehicle platforms, makes optimal use of limited installation space.

Another unique selling point is the ability to provide customized solutions for OEMs. Each component is individually adapted to specific requirements to ensure maximum safety and efficiency.

This is complemented by rigorous quality control and extensive testing, ensuring that Miba discharge resistors meet the highest automotive standards.

This unique combination makes Miba a reliable partner for the electromobility of today and tomorrow.