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Three common faults of power battery connection cable

2023-10-16

Power battery connection cable from the use point of view, should achieve the function is: the contact part of the conduction place must be conduction, reliable contact. The insulation parts that should not be connected must be insulated reliably. There are three common fatal failures of terminal cables:

1. Poor contact

The metal conductor inside the terminal connection wire is the core part of the terminal. It transfers the voltage, current or signal from the external wire or cable to the contact member corresponding to the connector. Therefore, the contact parts must have excellent structure, stable and reliable contact retention and good electrical conductivity. Due to the unreasonable structure design of contact parts, material selection error, mold instability, processing size is poor, rough surface, heat treatment plating and other surface treatment process is unreasonable, improper assembly, storage and use environment and improper operation, will cause poor contact in the contact parts and matching parts.

2. Poor insulation

The function of the insulator is to keep the contacts in the correct position, and to insulate each other between the contacts and the contacts and between the contacts and the shell. Therefore, the insulation parts must have excellent electrical properties, mechanical properties and process forming properties. Especially with the wide use of high density, miniaturized terminal connection wire, the effective wall thickness of insulator is getting thinner and thinner. This puts forward more stringent requirements on insulation materials, injection mold precision and molding process. Due to the existence of metal residues on the surface or inside the insulator, surface dust, flux and other pollution affected by moisture, organic material precipitates and harmful gas adsorption film and surface water film fusion to form ionic conductive channels, moisture absorption, long mold, aging insulation materials and other reasons, will cause short circuit, leakage, breakdown, low insulation resistance insulation phenomenon.

3. Improper fixation

Insulators not only insulate, but often provide precise neutralization protection for protruding contacts, but also have the function of positioning, locking and securing the device. Poor fixing, light impact contact reliable instantaneous power failure, serious is the disintegration of the product. Disintegration refers to the abnormal separation between the plug and socket and between the pin and the jack caused by the unreliable structure of the terminal connection line in the plugging state due to the material, design, process and other reasons, which will cause the interruption of the power transmission and signal control of the control system. Due to unreliable design, material selection error, improper selection of forming process, heat treatment, mold, assembly, welding and other process quality is poor, assembly is not in place will cause poor fixing due to positioning lock fit size is out of whack, processing quality consistency is poor, total separation force is too large and other reasons caused by poor exchange,it is a common disease, frequently occurring. These kinds of power battery connection cable faults can generally be detected and eliminated in time during inspection and use.

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