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CRESSALL'S SIMPLE SOLUTION TO ELECTRIC VEHICLE BRAKING AND HEATING PROBLEMS
The unique design of the Cressall EV resistor fully encapsulates the resistor element, separating it from the coolant. With sealing to IP56 level the construction protects the resistor from harmful dirt and pollution. This means they are robust and reliable, taking the surplus energy produced by the system turning it into heat which is absorbed into the cooling water.
This efficient heat transfer means that the excess energy can potentially be used elsewhere in the vehicle either for power pack pre-heating or cabin heating.
Cressall’s advanced electric vehicle resistors are light and compact, typically 10% of the size and 15% of the weight of an equivalent air cooled resistor and combine the normally incompatible qualities of high thermal conductivity with high electrical resistance by the use of patented materials and manufacturing processes.
The resistor is available as a heavy duty EV2 unit for large commercial and construction vehicles and the EVT for lighter applications.
All EV resistors are modular and are designed to fit together to match the braking power you need from 1kW to 100kW.
HOW THE CRESSALL EV RESISTOR FITS INTO YOUR ELECTRIC VEHICLE
The EV resistor’s small size, low weight and simple connections make it easy to install in any vehicle without the need for extensive re-engineering of existing components.
The EV can be integrated into the vehicle’s existing overall cooling system, so a separate, dedicated circuit is not required. Although the EV resistor assemblies can be supplied as individual components, Cressall offer different mounting solutions to cater for individual customer needs. These range from open bracket designs (to fit into existing enclosures) to complete custom designed enclosures, fabricated using our in house facilities.
EV2 THE HEAVY DUTY POWER SOLUTION
The EV2 has a high power rating of 25kW per module making it an extremely competitive proposition for heavy braking applications where compact size is paramount.
The high power per resistor, combined with modular design, makes this cutting edge technology the optimum choice for motor braking AC drives used in electric, hybrid and fuel cell powered vehicles.
The EV2 has been extensively trialled and and successfully installed in real world applications.
EVT ADVANCED VEHICLE RESISTOR
Our EVT resistor, with its 10kW power rating and extremely low pressure drop, provides the high reliability, mechanical simplicity and low weight demanded in passenger vehicles and is the most cost effective way to ensure any excess energy the vehicle produces is safely and efficiently recycled within the car itself.
This recovered energy can then be used for cabin heating rather than using a resistance only for heating, an extra drain on the vehicle’s batteries.
The need for three independent braking systems in hybrid/electric vehicles means that regenerative braking using the EVT is the greenest way for these vehicles to dissipate energy.
ELECTRIC VEHICLE EMERGENCY BRAKING
The legal requirement of the R13 Type IIA Test for three independent braking systems on battery powered vehicles has previously proved almost impossible to meet.
With a fully loaded battery the vehicle’s kinetic energy cannot be converted into electricity and stored, meaning no emergency braking is available.
Fitting an EV2 solves this problem by converting excess electricity into hot water within the BEV’s own cooling system and doing so instantly. All without the expected weight penalty whilst simultaneously protecting the vehicle’s most expensive component – the battery pack.
The latest hybrid/electric vehicle developments mean there is an urgent need for a new approach to regenerative braking.
Our EV2 resistor provides the higher reliability, mechanical simplicity and low weight demanded and the EV2 is the most cost effective way to ensure any excess energy produced is safely and efficiently recycled within the vehicle itself.
The EV2 is the most cost effective way to ensure any excess energy produced is safely and efficiently recycled within the vehicle itself.
Units can be combined together to handle from 25kW to 600kW and supplied as individual components, frame mounted assemblies for integration in customer’s systems or completely enclosed multi-banked systems that include inlet/outlet manifolds, flow and temperature monitoring.
Regenerative braking using the EV2 is the greenest way for battery, hybrid and fuel cell vehicles to dissipate energy.
DOWNHILL TEST FOR FULLY LOADED 8 TON TRUCK
g = GRAVITY FORCE
Fa = AIR RESISTANCE
Fr = ROLLING RESISTANCE
SLOPE = 7%
6 km track at constant 30 km/h
To meet the legal requirement, the braking resistor must have the capacity to absorb 33MJ of energy. Cressall’s solution to this would be 1 x 3EV2, rated for 50kW.
BATTERY AND CABIN HEATING
Low temperatures greatly reduce the power and efficiency of any vehicle’s battery pack or fuel cell. During the charging cycle the EV2 ensures the battery is able to operate effectively in colder weather but also makes the vehicle more comfortable for driver and passengers.
Our resistors provide heating to the EV’s cabin for the driver’s and passengers’ comfort and pre-heating to the vehicle’s batteries or fuel cells to guarantee immediate peak performance – at any temperature.
