On-Board
Our official sales partner: Shivalik Bimetal Controls Ltd.
Shivalik Bimetal Controls Ltd. specializes in bonding materials through processes such as diffusion bonding, cladding, electron beam bonding, soldering and resistance welding and offers a wide range of products for various industries.
Through this partnership, we can offer our customers access to a wide range of state-of-the-art technologies and products - from current sense resistors (also known as shunt resistors) for efficient energy measurement to customized solutions for industrial applications and consumer electronics.
Through this partnership, we can offer our customers access to a wide range of state-of-the-art technologies and products - from current sense resistors (also known as shunt resistors) for efficient energy measurement to customized solutions for industrial applications and consumer electronics.
Product range of our on-board current sense
Our on-board current sense resistors from Shivalik Bimetal Controls Ltd. offer the highest precision and reliability for demanding electronic systems. Thanks to their low temperature coefficient, high resistance stability and optimal heat dissipation, they ensure efficient current measurement with minimal energy loss.
Below you will find an overview of our products with detailed specifications and data sheets to help you find the right solution for your requirements.
Below you will find an overview of our products with detailed specifications and data sheets to help you find the right solution for your requirements.
On-Board
| Resistance | 0 - 10 mΩ, 0.3 - 5 mΩ, 0.045 - 0.50 mΩ, 0.1 - 3 mΩ, 0.2 - 5 mΩ, 1 - 50 mΩ, 0.3 - 2 mΩ, 0.1 - 5 mΩ, 0.2 mΩ, 4 - 5 mΩ, 0.2 to 3 mΩ, 0 mΩ |
| Size | 1206-5930, 4512/4524, 4521/4527 |
| Power | 6 - 1.5 W, 6 - 2.5 W, 12 W, 2-15 - 5 W, 12 - 3 W, 5 - 2 W |
| Resistance Tolerance | 1% 2% 5%, 1% 2% 4%, 1% 5%, 1% 3% 5%, N.A. |
On-board current measuring resistors for industrial applications
Buy on-board shunt resistors
- High efficiency - Minimizes energy losses
- Less heat - Longer service life
- Wide range of applications - current monitoring in electronics and industry
- Reliable - Quality from Rotima & Shivalik
Customized on-board shunt modules - development with Rotima
Rotima works with you to develop customized shunt modules that are precisely tailored to your requirements. Thanks to our close cooperation with leading suppliers and our expertise in precision components, we offer individual solutions for a wide range of applications, for example in the power supply, measurement technology and automotive industries.
Our development processes guarantee maximum precision in terms of resistance value, tolerances, thermal load capacity and design. Thanks to our customer-oriented cooperation, we implement your projects efficiently and reliably.
Let us develop innovative solutions together - contact us to find out more about the individual design of your shunt modules!
Our development processes guarantee maximum precision in terms of resistance value, tolerances, thermal load capacity and design. Thanks to our customer-oriented cooperation, we implement your projects efficiently and reliably.
Let us develop innovative solutions together - contact us to find out more about the individual design of your shunt modules!
Do you have any questions about our offer?
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Current measuring resistor
On-Board
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High-precision on-board shunt modules for current measurement
High-precision shunt modules enable accurate current measurement by recording the voltage drop with minimal resistance. By using low-resistance materials with high temperature stability, they ensure reliable performance over a wide measuring range.
Modern manufacturing technologies such as electron beam welding and diffusion bonding ensure uniform resistance distribution and minimize thermal influences. As a result, the modules remain stable and durable even at high currents and extreme ambient temperatures.
These shunt modules are essential for battery management systems (BMS), energy measuring devices and industrial applications where maximum measuring accuracy is required. Thanks to customer-specific designs, the resistance value, design and thermal load capacity can be optimally adapted to the respective requirements.
Modern manufacturing technologies such as electron beam welding and diffusion bonding ensure uniform resistance distribution and minimize thermal influences. As a result, the modules remain stable and durable even at high currents and extreme ambient temperatures.
These shunt modules are essential for battery management systems (BMS), energy measuring devices and industrial applications where maximum measuring accuracy is required. Thanks to customer-specific designs, the resistance value, design and thermal load capacity can be optimally adapted to the respective requirements.
Our range of other current measuring resistors:
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Design and function of on-board shunt resistors
An on-board current measuring resistor is an external resistor whose purpose is to reliably measure high currents. Its positioning outside the actual circuit ensures effective heat dissipation and leads to an improvement in measurement accuracy. The special design with precise resistor elements made of copper and resistor alloys ensures stable measurement results, even under high loads.
During the measurement, a small voltage is generated which is proportional to the flowing current. This can be evaluated to determine the exact current. An on-board current measuring resistor is often used in energy management systems, industrial systems or high-performance batteries.
Rotima AG offers customized solutions for various applications and is characterized by durable materials and precise manufacturing. An on-board current measuring resistor ensures reliable and accurate current monitoring and contributes to increasing the efficiency of your systems.
During the measurement, a small voltage is generated which is proportional to the flowing current. This can be evaluated to determine the exact current. An on-board current measuring resistor is often used in energy management systems, industrial systems or high-performance batteries.
Rotima AG offers customized solutions for various applications and is characterized by durable materials and precise manufacturing. An on-board current measuring resistor ensures reliable and accurate current monitoring and contributes to increasing the efficiency of your systems.
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What can we do for you?
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Further information on on-board current measuring resistors
Here you will find comprehensive information on on-board current measuring resistors - from how they work and their advantages to areas of application and the right product selection. Our FAQ section will help you to find the optimum solution for your individual requirements. If you have any further questions or require personal advice, please do not hesitate to contact us at any time.
How does an on-board current measuring resistor work in a battery management system (BMS)?
An on-board current measuring resistor in the battery management system (BMS) is used to precisely measure the electrical current flowing through the battery. The resistor generates a small but measurable voltage drop that is directly proportional to the flowing current according to Ohm's law U=R⋅IU=R⋅I. This voltage is recorded by a microcontroller or a special analog-to-digital converter (ADC) and used to monitor and control the charging process.
By precisely measuring the current, the BMS can determinethe state of charge (SoC) and state of health (SoH) of the battery. This is crucial for optimal battery life and efficient energy use, especially in electric vehicles and portable devices. A high-quality current measuring resistor with a low temperature coefficient and high stability ensures reliable data acquisition.
Another important feature is the low self-heating of the resistor, as high currents flow and power losses must be minimized. Modern electron beam welding processes and diffusion bonding improve the long-term stability of the resistor and minimize measurement errors due to thermal effects. In a well-coordinated BMS system, the on-board current measuring resistor makes a significant contribution to battery safety, performance optimization and increased efficiency.
By precisely measuring the current, the BMS can determinethe state of charge (SoC) and state of health (SoH) of the battery. This is crucial for optimal battery life and efficient energy use, especially in electric vehicles and portable devices. A high-quality current measuring resistor with a low temperature coefficient and high stability ensures reliable data acquisition.
Another important feature is the low self-heating of the resistor, as high currents flow and power losses must be minimized. Modern electron beam welding processes and diffusion bonding improve the long-term stability of the resistor and minimize measurement errors due to thermal effects. In a well-coordinated BMS system, the on-board current measuring resistor makes a significant contribution to battery safety, performance optimization and increased efficiency.
What materials are used for high-precision on-board shunt resistors?
High-precision on-board shunt resistors are made of special resistor alloys that are known for their high temperature stability and low resistance tolerances. Commonly used materials include manganin, a copper-manganese-nickel alloy, as well as nichrome (nickel-chromium) and special stainless steel variants. These materials are characterized by low thermal drift, which means that their resistance value remains constant even with temperature fluctuations.
An essential element of the design is the connection of copper to the resistor alloy, as the shunt is contacted directly with copper circuit boards or cables in most applications. Electron beam welding or diffusion bonding can be used to create a stable, long-term connection that reduces the occurrence of thermoelectric effects (thermo-EMF). These effects could otherwise lead to unwanted voltage deviations and impair measurement accuracy.
In addition, many precisionshunts are provided with a protective coating or surface treatment to prevent corrosion and material ageing. Particularly in demanding environments such as automotive and industrial electronics, the resistors must be mechanically robust, chemically resistant and electrically reliable. The choice of material is therefore crucial for the longevity, precision and efficiency of the on-board shunt resistor.
An essential element of the design is the connection of copper to the resistor alloy, as the shunt is contacted directly with copper circuit boards or cables in most applications. Electron beam welding or diffusion bonding can be used to create a stable, long-term connection that reduces the occurrence of thermoelectric effects (thermo-EMF). These effects could otherwise lead to unwanted voltage deviations and impair measurement accuracy.
In addition, many precisionshunts are provided with a protective coating or surface treatment to prevent corrosion and material ageing. Particularly in demanding environments such as automotive and industrial electronics, the resistors must be mechanically robust, chemically resistant and electrically reliable. The choice of material is therefore crucial for the longevity, precision and efficiency of the on-board shunt resistor.
How do temperature coefficient and resistance tolerance influence the accuracy of an on-board current measuring resistor?
The temperature coefficient of resistance (TCR) describes how much the resistance value of a shunt resistor changes with temperature fluctuations. A low TCR value is crucial for high-precision current measurements, as it ensures that the resistance does not change due to environmental influences or self-heating. Resistors with manganese or other special alloys have a particularly low TCR value and are therefore widely used in precision applications.
The resistance tolerance indicates how much the actual resistance value can deviate from the nominal value. For highly accurate measurements in battery management systems, industrial electronics and automotive applications, tolerances in the range of ±0.1 % or better are required. If the deviation is too high, the measured currents may be inaccurate, which in turn affects the efficiency and safety of the entire system.
In addition, self-heating due to high currents affects both the temperature coefficient and the long-term stability of the resistor. By selecting materials with low thermal drift and minimal power loss, measurement errors can be reduced. The combination of low temperature coefficient and precise resistance tolerance thus ensures stable, reliable and accurate current measurement in sensitive applications.
The resistance tolerance indicates how much the actual resistance value can deviate from the nominal value. For highly accurate measurements in battery management systems, industrial electronics and automotive applications, tolerances in the range of ±0.1 % or better are required. If the deviation is too high, the measured currents may be inaccurate, which in turn affects the efficiency and safety of the entire system.
In addition, self-heating due to high currents affects both the temperature coefficient and the long-term stability of the resistor. By selecting materials with low thermal drift and minimal power loss, measurement errors can be reduced. The combination of low temperature coefficient and precise resistance tolerance thus ensures stable, reliable and accurate current measurement in sensitive applications.
What are the differences between on-board and off-board current measuring resistors in power monitoring?
On-board current measuring resistors are integrated directly into electronic circuits and enable compact, precise measurement of the current within the system. They are often used inbattery management systems, switching power supplies and automotive control systems where continuous and precise current monitoring is required. Due to their integration into the circuit board or system layout, they are thermally optimized to minimize self-heating and measurement errors.
Off-board current measuring resistors, on the other hand, are designed as external modules that are mounted outside the main circuit. They are particularly suitable for high-current applications where the heat generated needs to be dissipated more effectively. As they are often larger in size and made of resistant materials, they can measure very high currents with minimal resistance tolerance and are ideal for industrial energy measurement systems, battery storage solutions and power monitoring in electromobility.
The main difference therefore lies in the design, the thermal load capacity and the maximum current they can measure. While on-board current measuring resistors are optimized for compact systems with low to medium currents, off-board variants offer a more robust solution for high-current applications with better heat dissipation. Both variants are essential for precise and reliable power monitoring in modern electronic systems.
Off-board current measuring resistors, on the other hand, are designed as external modules that are mounted outside the main circuit. They are particularly suitable for high-current applications where the heat generated needs to be dissipated more effectively. As they are often larger in size and made of resistant materials, they can measure very high currents with minimal resistance tolerance and are ideal for industrial energy measurement systems, battery storage solutions and power monitoring in electromobility.
The main difference therefore lies in the design, the thermal load capacity and the maximum current they can measure. While on-board current measuring resistors are optimized for compact systems with low to medium currents, off-board variants offer a more robust solution for high-current applications with better heat dissipation. Both variants are essential for precise and reliable power monitoring in modern electronic systems.
