Braking Resistor Systems

Our Radial Braking Resistors are recognized for their best-in-class lifecycle, which translates into significant cost savings through reduced maintenance and enhanced system longevity. The comprehensive design integrates all necessary components — including the motor, fan, resistor, top cover, and cables — into a single, compact unit that simplifies installation and increases reliability.

Engineered with advanced materials and cutting-edge technology, these resistor systems are tailored to withstand extreme conditions while managing kinetic energy effectively during the braking process without compromising performance. They are specifically optimized for high-load capacities and continuous operation, making them ideal for applications requiring robust and efficient braking solutions.

• Best-in-class lifecycle: Significantly reduces maintenance and enhances system longevity, leading to cost savings
• Integrated design: Includes motor, fan, resistor, top cover, and cables, all in a single, compact unit for easy installation and improved reliability
• Advanced materials and technology: Engineered for durability and performance in extreme conditions, managing kinetic energy effectively
• Optimized for high-load capacities: Ideal for continuous operation in demanding environments
• Power levels: Capable of handling up to and exceeding 4.5 MW
• Dynamic braking: Supports designs exceeding 940 amps and 2800 volts (bus)
• Tight resistance tolerances: +/- 1.5% for precise performance
• Radial fan integration: Resistor element placement matches the radial fan profile, providing unmatched capability and reliability
• Flexible discharge options: Vertical or horizontal discharge configurations
• Easy maintenance: Designed for simplified maintenance routines
• Cost-efficient: Lower cost per kW at high power levels
• Proven durability: Decades of safe, reliable, and durable operation in the most grueling environments
• Weight savings: Overall 1% weight savings, contributing to more efficient system performance

We’re here to help! Contact us for comprehensive support and expert advice on our products. Reach out today to ensure you get all the information you need to make informed decisions.

White Paper – Smart Grid Technology for Predictive Analytics of Grid Resistor Life

• Locomotive
• Mining
• Maintenance of Way

Dayton-Phoenix Group’s Komatsu 930E and 830E aftermarket solution will take your haul truck to the next level. In the tough environment of mining, a 1% weight savings with our aftermarket radial braking grid design can make a significant impact. Compared to the less efficient and heavier OEM model, this reduction allows you to add 1.5 tons more payload to each haul truck, boosting your productivity without compromising performance.

The enhanced fuel efficiency and quicker cycle times with improved braking performance can also mean fewer trucks are needed in service, reducing both operational costs and fleet maintenance. This 1% weight savings helps make your mining operations more efficient, sustainable, and profitable. A mere 1% –  a small change with a big impact.

• Radial replacement: Designed specifically for Komatsu 830E and 930E haul trucks
• Significant weight savings: Reduces weight by 3,100 lbs, allowing for an additional 1.5 tons of payload per truck
• Improved fuel efficiency: Enhanced braking performance leads to better fuel economy, contributing to lower operational costs
• Quicker cycle times: Improved braking translates to faster truck cycles, increasing productivity
• Fewer trucks needed: Optimized braking can reduce the number of trucks required in service, minimizing fleet size and maintenance costs
• Lower life-cycle cost: Designed to deliver cost savings over the lifespan of the equipment
• Optimized air flow: Efficient air flow management ensures consistent performance and durability in harsh mining environments
• Increased operational efficiency: The 1% weight reduction contributes to overall system efficiency and sustainability, improving profitability

We’re here to help! Contact us for comprehensive support and expert advice on our products. Reach out today to ensure you get all the information you need to make informed decisions.

Komatsu Aftermarket Information

• Komatsu 930E and 830E Haul Trucks

Liquid Cooled Resistor systems offer advanced thermal management solutions tailored for applications where high power dissipation and space optimization are critical. These systems are ideal for environments that demand robust performance but are limited by thermal constraints, such as in electric vehicles, power converters, and industrial automation.

Utilizing a liquid cooling mechanism, these resistors efficiently manage heat by circulating a coolant through sealed channels within the resistor unit. This process significantly enhances heat dissipation compared to air-cooled systems, allowing for higher power capacities and more compact designs.

• Advanced thermal management: Efficient liquid cooling mechanism for superior heat dissipation in high-power applications
• Ideal for thermal-constrained environments: Tailored for use in electric vehicles, power converters, and industrial automation where space and heat management are critical
• Enhanced thermal efficiency: Operates at lower temperatures, extending system life and improving safety compared to air-cooled systems
• Higher power capacity: Allows for greater power dissipation in a more compact design, enabling better performance in high-demand settings
• Compact footprint: The cooling mechanism reduces overall system size, making it easy to integrate into space-constrained applications
• Customizable configurations: Available in various configurations and cooling options to meet specific application requirements for optimal performance
• Robust design: Sealed channels for coolant circulation ensure durability and reliability in challenging environments
• Increased system longevity: Improved cooling enhances operational life by preventing overheating and reducing wear on components

We’re here to help! Contact us for comprehensive support and expert advice on our products. Reach out today to ensure you get all the information you need to make informed decisions.

• Locomotive
• Mining
• Maintenance of Way
• Transit
• Industrial
• Agricultural
• Marine
• Military
• Power Generation

Our custom load cell systems provide accurate and reliable measurement solutions tailored specifically to your application requirements. Our load cells are essential for applications that require load measurement in industries such as rail, mining, marine, agriculture, aerospace, automotive, and industrial automation.

• Tailored measurement solutions: Custom-designed load cells for precise and reliable load measurement across various industries, including rail, mining, marine, agriculture, aerospace, automotive, and industrial automation
• Cooling options: Air-blown and free-air convection-cooled designs available for optimized performance in diverse environments
• Advanced insulation materials: Incorporates the latest insulating technologies to ensure safety and longevity
• Custom resistor elements: Materials tailored to meet specific resistance, watt density, inductance, and mechanical requirements
• Stainless steel structures: All stainless steel hardware and structures available for added durability and corrosion resistance where required
• High voltage capabilities: Suitable for operating voltages up to 4,500 volts, meeting the needs of high-power applications
• AC and DC grids: Versatility in power types, offering both AC and DC grid configurations
• Flexible packaging: Roof-top and under-car packaging options to accommodate space and design constraints
• Proven design concepts: Custom designs utilizing Dayton-Phoenix Group’s proven manufacturing technology and engineering expertise
• Optimized footprint: Load cell systems are designed to fit specific dimensional and operational requirements for seamless integration

We’re here to help! Contact us for comprehensive support and expert advice on our products. Reach out today to ensure you get all the information you need to make informed decisions.

• Locomotive
• Mining
• Maintenance of Way
• Transit
• Industrial
• Agricultural
• Marine
• Military
• Power Generation

Our High Voltage Resistor systems are expertly designed to manage high voltage currents safely and efficiently, crucial for industries such as power distribution, telecommunications, and industrial processing. These systems are particularly tailored to withstand the harsh conditions found in the cramped and challenging environments of locomotives, caustic wash solutions, under transit cars, or on the rooftops of electric buses.

Engineered to function and endure for over 20 years in environments characterized by dust, vibration, and humidity.

• Expert design for high voltage management: Tailored to handle high voltage currents safely and efficiently in industries like power distribution, telecommunications, and industrial processing
• Long-term durability: Engineered to function and endure for over 20 years in harsh environments characterized by dust, vibration, and humidity
• Cooling options: Available in both air-blown and free-air convection-cooled designs for flexible thermal management
• Advanced insulation: Uses the latest insulating materials to ensure optimal performance and safety
• Custom resistor elements: Materials engineered to meet specific resistance, watt density, inductance, and mechanical requirements
• Stainless steel hardware: All stainless steel structures and hardware available where required for enhanced durability and corrosion resistance
• High voltage capacity: Supports operating voltages up to 4,500 volts for high-power applications
• AC and DC grid compatibility: Available in both AC and DC grid configurations for versatile application needs
• Flexible packaging options: Designed for roof-top and under-car installations to accommodate space constraints and environmental challenges
• Custom designs available: Tailored to specific application requirements using proven design concepts and advanced manufacturing technology
• Optimized footprint: Systems are designed to fit desired space and operational constraints for seamless integration

We’re here to help! Contact us for comprehensive support and expert advice on our products. Reach out today to ensure you get all the information you need to make informed decisions.

• Locomotive
• Mining
• Maintenance of Way
• Transit
• Industrial
• Agricultural
• Marine
• Military
• Power Generation