Variable resistors

Adjustable resistors



A resistor may have one or more fixed tapping points so that the resistance can be changed by moving the connecting wires to different terminals. Some wirewound power resistors have a tapping point that can slide along the resistance element, allowing a larger or smaller part of the resistance to be used.
Where continuous adjustment of the resistance value during operation of equipment is required, the sliding resistance tap can be connected to a knob accessible to an operator. Such a device is called a rheostat and has two terminals.
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 Potentiometers

A common element in electronic devices is a three-terminal resistor with a continuously adjustable tapping point controlled by rotation of a shaft or knob. These variable resistors are known as potentiometers when all three terminals are present, since they act as a continuously adjustable voltage divider. A common example is a volume control for a radio receiver.
Accurate, high-resolution panel-mounted potentiometers (or "pots") have resistance elements typically wirewound on a helical mandrel, although some include a conductive-plastic resistance coating over the wire to improve resolution. These typically offer ten turns of their shafts to cover their full range. They are usually set with dials that include a simple turns counter and a graduated dial. Electronic analog computers used them in quantity for setting coefficients, and delayed-sweep oscilloscopes of recent decades included one on their panels.
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Resistance decade boxes

A resistance decade box or resistor substitution box is a unit containing resistors of many values, with one or more mechanical switches which allow any one of various discrete resistances offered by the box to be dialed in. Usually the resistance is accurate to high precision, ranging from laboratory/calibration grade accuracy of 20 parts per million, to field grade at 1%. Inexpensive boxes with lesser accuracy are also available. All types offer a convenient way of selecting and quickly changing a resistance in laboratory, experimental and development work without needing to attach resistors one by one, or even stock each value. The range of resistance provided, the maximum resolution, and the accuracy characterize the box. For example, one box offers resistances from 0 to 24 megohms, maximum resolution 0.1 ohm, accuracy 0.1%.
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Special devices

There are various devices whose resistance changes with various quantities. The resistance of thermistors exhibit a strong negative temperature coefficient, making them useful for measuring temperatures. Since their resistance can be large until they are allowed to heat up due to the passage of current, they are also commonly used to prevent excessive current surges when equipment is powered on. Metal oxide varistors drop to a very low resistance when a high voltage is applied, making them useful for protecting electronic equipment by absorbing dangerous voltage surges. One sort of photodetector, the photoresistor, has a resistance which varies with illumination.
The strain gauge, invented by Edward E. Simmons and Arthur C. Ruge in 1938, is a type of resistor that changes value with applied strain. A single resistor may be used, or a pair (half bridge), or four resistors connected in a Wheatstone bridge configuration. The strain resistor is bonded with adhesive to an object that will be subjected to mechanical strain. With the strain gauge and a filter, amplifier, and analog/digital converter, the strain on an object can be measured.
A related but more recent invention uses a Quantum Tunnelling Composite to sense mechanical stress. It passes a current whose magnitude can vary by a factor of 1012 in response to changes in applied pressure.

 Measurement

The value of a resistor can be measured with an ohmmeter, which may be one function of a multimeter. Usually, probes on the ends of test leads connect to the resistor. A simple ohmmeter may apply a voltage from a battery across the unknown resistor (with an internal resistor of a known value in series) producing a current which drives a meter movement. The current flow, in accordance with Ohm's Law, is inversely proportional to the sum of the internal resistance and the resistor being tested, resulting in an analog meter scale which is very non-linear, calibrated from infinity to 0 ohms. A digital multimeter, using active electronics, may instead pass a specified current through the test resistance. The voltage generated across the test resistance in that case is linearly proportional to its resistance, which is measured and displayed. In either case the low-resistance ranges of the meter pass much more current through the test leads than do high-resistance ranges, in order for the voltages present to be at reasonable levels (generally below 10 volts) but still measurable.

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Measuring low-value resistors, such as fractional-ohm resistors, with acceptable accuracy requires four-terminal connections. One pair of terminals applies a known, calibrated current to the resistor, while the other pair senses the voltage drop across the resistor. Some laboratory quality ohmmeters, especially milliohmmeters, and even some of the better digital multimeters sense using four input terminals for this purpose, which may be used with special test leads. Each of the two so-called Kelvin clips has a pair of jaws insulated from each other. One side of each clip applies the measuring current, while the other connections are only to sense the voltage drop. The resistance is again calculated using Ohm's Law as the measured voltage divided by the applied current.

 Standards

 Production resistors

Resistor characteristics are quantified and reported using various national standards. In the US, MIL-STD-202  contains the relevant test methods to which other standards refer.
There are various standards specifying properties of resistors for use in equipment:
  • BS 1852
  • EIA-RS-279
  • MIL-PRF-26
  • MIL-PRF-39007 (Fixed Power, established reliability)
  • MIL-PRF-55342 (Surface-mount thick and thin film)
  • MIL-PRF-914
  • MIL-R-11
  • MIL-R-39017 (Fixed, General Purpose, Established Reliability)
  • MIL-PRF-32159 (zero ohm jumpers)
There are other United States military procurement MIL-R- standards.

 Resistance standards

The primary standard for resistance, the "mercury ohm" was initially defined in 1884 in as a column of mercury 106 mm long and 1 square millimeter in cross-section, at 0 degrees Celsius. Difficulties in precisely measuring the physical constants to replicate this standard result in variations of as much as 30 ppm. From 1900 the mercury ohm was replaced with a precision machined plate of manganin[12]. Since 1990 the international resistance standard has been based on the quantized Hall effect discovered by Klaus von Klitzing, for which he won the Nobel Prize in Physics in 1985.[13]
Resistors of extremely high precision are manufactured for calibration and laboratory use. They may have four terminals, using one pair to carry an operating current and the other pair to measure the voltage drop; this eliminates errors caused by voltage drops across the lead resistances, because no current flows through voltage sensing leads. It is important in small value resistors (100–0.0001 ohm) where lead resistance is significant or even comparable with respect to resistance standard value.[14]

 Resistor marking

Most axial resistors use a pattern of colored stripes to indicate resistance. Surface-mount resistors are marked numerically, if they are big enough to permit marking; more-recent small sizes are impractical to mark. Cases are usually tan, brown, blue, or green, though other colors are occasionally found such as dark red or dark gray.


Early 20th century resistors, essentially uninsulated, were dipped in paint to cover their entire body for color coding. A second color of paint was applied to one end of the element, and a color dot (or band) in the middle provided the third digit. The rule was "body, tip, dot", providing two significant digits for value and the decimal multiplier, in that sequence. Default tolerance was ±20%. Closer-tolerance resistors had silver (±10%) or gold-colored (±5%) paint on the other end.

Four-band resistors

Four-band identification is the most commonly used color-coding scheme on resistors. It consists of four colored bands that are painted around the body of the resistor. The first two bands encode the first two significant digits of the resistance value, the third is a power-of-ten multiplier or number-of-zeroes, and the fourth is the tolerance accuracy, or acceptable error, of the value. The first three bands are equally spaced along the resistor; the spacing to the fourth band is wider. Sometimes a fifth band identifies the thermal coefficient, but this must be distinguished from the true 5-color system, with 3 significant digits.
For example, green-blue-yellow-red is 56×104 Ω = 560 kΩ ± 2%. An easier description can be as followed: the first band, green, has a value of 5 and the second band, blue, has a value of 6, and is counted as 56. The third band, yellow, has a value of 104, which adds four 0's to the end, creating 560,000 Ω at ±2% tolerance accuracy. 560,000 Ω changes to 560 kΩ ±2% (as a kilo- is 103).
Each color corresponds to a certain digit, progressing from darker to lighter colors, as shown in the chart below.
Color 1st band 2nd band 3rd band (multiplier) 4th band (tolerance) Temp. Coefficient
Black 0 0 ×100

Brown 1 1 ×101 ±1% (F) 100 ppm
Red 2 2 ×102 ±2% (G) 50 ppm
Orange 3 3 ×103
15 ppm
Yellow 4 4 ×104
25 ppm
Green 5 5 ×105 ±0.5% (D)
Blue 6 6 ×106 ±0.25% (C)
Violet 7 7 ×107 ±0.1% (B)
Gray 8 8 ×108 ±0.05% (A)
White 9 9 ×109

Gold

×10−1 ±5% (J)
Silver

×10−2 ±10% (K)
None


±20% (M)
There are many mnemonics for remembering these colors.

Resistors




A typical axial-lead resistor
Three carbon composition resistors in a 1960s valve (vacuum tube) radio

Axial-lead resistors on tape.
Components used to resist current.

   1. See the Transducer section below for resistors used to sense environmental conditions (Thermistor, Photo resistor, RTD...)
   2. See the Protection section below for resistors used for current or voltage limiting (MOV, Inrush Limiters...)


    * Resistor - fixed value
    * Resistor network - array of resistors in one package
    * Trimmer - Small variable resistor
    * Potentiometer, Rheostat - variable resistor
    * Heater - heating element
    * Resistance wire - wire of high-resistance material, similar to heating element
    * Thermistor - temperature-varied resistor
    * Varistor - voltage-varied resistor

A resistor is a two-terminal electronic component that produces a voltage across its terminals that is proportional to the electric current through it in accordance with Ohm's law:

    V = IR

Resistors are elements of electrical networks and electronic circuits and are ubiquitous in most electronic equipment. Practical resistors can be made of various compounds and films, as well as resistance wire (wire made of a high-resistivity alloy, such as nickel-chrome).

The primary characteristics of a resistor are the resistance, the tolerance, the maximum working voltage and the power rating. Other characteristics include temperature coefficient, noise, and inductance. Less well-known is critical resistance, the value below which power dissipation limits the maximum permitted current, and above which the limit is applied voltage. Critical resistance is determined by the design, materials and dimensions of the resistor.
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Resistors can be integrated into hybrid and printed circuits, as well as integrated circuits. Size, and position of leads (or terminals), are relevant to equipment designers; resistors must be physically large enough not to overheat when dissipating their power.

Units

The ohm (symbol: Ω) is the SI unit of electrical resistance, named after Georg Simon Ohm. Commonly used multiples and submultiples in electrical and electronic usage are the milliohm (1x10−3), kilohm (1x103), and megohm (1x106).

Lead arrangements

Through-hole components typically have leads leaving the body axially. Others have leads coming off their body radially instead of parallel to the resistor axis

Other components may be SMT (surface mount technology) while high power resistors may have one of their leads designed into the heat sink.

Carbon composition  

Carbon composition resistors consist of a solid cylindrical resistive element with embedded wire leads or metal end caps to which the lead wires are attached. The body of the resistor is protected with paint or plastic. Early 20th-century carbon composition resistors had uninsulated bodies; the lead wires were wrapped around the ends of the resistance element rod and soldered. The completed resistor was painted for color coding of its value.
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The resistive element is made from a mixture of finely ground (powdered) carbon and an insulating material (usually ceramic). A resin holds the mixture together. The resistance is determined by the ratio of the fill material (the powdered ceramic) to the carbon. Higher concentrations of carbon, a weak conductor, result in lower resistance. Carbon composition resistors were commonly used in the 1960s and earlier, but are not so popular for general use now as other types have better specifications, such as tolerance, voltage dependence, and stress (carbon composition resistors will change value when stressed with over-voltages). Moreover, if internal moisture content (from exposure for some length of time to a humid environment) is significant, soldering heat will create a non-reversible change in resistance value. These resistors, however, if never subjected to overvoltage nor overheating were remarkably reliable considering the component's size [1]

They are still available, but comparatively quite costly. Values ranged from fractions of an ohm to 22 megohms. Because of the high price, these resistors are no longer used in most applications. However, carbon resistors are used in power supplies and welding controls[1].
[edit] Carbon film

A carbon film is deposited on an insulating substrate, and a helix cut in it to create a long, narrow resistive path. Varying shapes, coupled with the resistivity of carbon, (ranging from 90 to 400 nΩm) can provide a variety of resistances.[2] Carbon film resistors feature a power rating range of 0.125 W to 5 W at 70 °C. Resistances available range from 1 ohm to 10 megohm. The carbon film resistor has an operating temperature range of -55 °C to 155 °C. It has 200 to 600 volts maximum working voltage range.[3]. Special carbon film resistors are used in applications requiring high pulse stability[1].


 Metal film

A common type of axial resistor today is referred to as a metal-film resistor. Metal electrode leadless face (MELF) resistors often use the same technology, but are a cylindrically shaped resistor designed for surface mounting. Note that other types of resistors (e.g., carbon composition) are also available in MELF packages.

Metal film resistors are usually coated with nickel chromium (NiCr), but might be coated with any of the cermet materials listed above for thin film resistors. Unlike thin film resistors, the material may be applied using different techniques than sputtering (though that is one such technique). Also, unlike thin-film resistors, the resistance value is determined by cutting a helix through the coating rather than by etching. (This is similar to the way carbon resistors are made.) The result is a reasonable tolerance (0.5, 1, or 2%) and a temperature coefficient that is generally between 50 and 100 ppm/K.[4]. Metal film resistors possess good noise characteristics and low non-linearity due to a low voltage coefficient. Also beneficial are the components efficient tolerance, temperature coefficient and stability[1].

Metal Oxide film

Metal-Oxide film resistors resemble Metal film types, but are made of metal oxides such as tin oxide. This results in a higher operating temperature and greater stability/reliability than Metal film. They are used in applications with high endurance demands.

Wirewound


Types of windings in wire resistors:
1 - common
2 - bifilar
3 - common on a thin former
4 - Ayrton-Perry

Wirewound resistors are commonly made by winding a metal wire, usually nichrome, around a ceramic, plastic, or fiberglass core. The ends of the wire are soldered or welded to two caps or rings, attached to the ends of the core. The assembly is protected with a layer of paint, molded plastic, or an enamel coating baked at high temperature. Because of the very high surface temperature these resistors can withstand temperatures of up to +450 °C[1]. Wire leads in low power wirewound resistors are usually between 0.6 and 0.8 mm in diameter and tinned for ease of soldering. For higher power wirewound resistors, either a ceramic outer case or an aluminum outer case on top of an insulating layer is used. The aluminum-cased types are designed to be attached to a heat sink to dissipate the heat; the rated power is dependent on being used with a suitable heat sink, e.g., a 50 W power rated resistor will overheat at a fraction of the power dissipation if not used with a heat sink. Large wirewound resistors may be rated for 1,000 watts or more.
Because wirewound resistors are coils they have more undesirable inductance than other types of resistor, although winding the wire in sections with alternately reversed direction can minimize inductance. Other techniques employ bifilar winding, or a flat thin former (to reduce cross-section area of the coil). For most demanding circuits resistors with Ayrton-Perry winding are used.
Applications of wirewound resistors are similar to those of composition resistors with the exception of the high frequency. The high frequency of wirewound resistors is substantially worse than that of a composition resistor




Electronic components



An electronic component is a basic electronic element usually packaged in a discrete form with two or more connecting leads or metallic pads. Components are intended to be connected together, usually by soldering to a printed circuit board, to create an electronic circuit with a particular function (for example an amplifier, radio receiver, or oscillator). Components may be packaged singly (resistor, capacitor, transistor, diode etc.) or in more or less complex groups as integrated circuits (operational amplifier, resistor array, logic gate etc.)
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Various components
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