Common Problems Analysis of Electric Vehicle Cables

The safe operation of the circuit is directly determined by the quality of the electric vehicle cables. Unpredictable damage to life and economy can occur if the circuit can’t run safely and stably. Therefore, when choosing electric vehicle cables, we need to choose those which are reputable and trusted. There are generally two reasons for the problems encountered when using electric vehicle cables. Firstly, they are caused by using poor quality EV cables which have serious issues when manufactured. Secondly, these problems can be caused by improperly using or maintaining electric vehicle cables. So what are the most common causes of electric vehicle cable problems?

Basic knowledge of electric vehicle cables

The connection between electric vehicles and charging stations is provided by electric vehicle cables. Their basic function is to transfer electrical energy. However, with the development of charging technology, to complete the charging process more effectively, it is necessary to establish good communication between the electric vehicle and the charging station and to make automatic adjustments when required. As a result, the requirements for charging cables are increasing. Charging cables must not only have the function of transmitting electricity. They must also transmit the status and information of the vehicle and the power battery to the charging station to realize real-time interaction. To complete the charging process safely and reliably, the charging behavior should be adjusted as necessary.

Common causes of problems with electric vehicle cables include

Structural mismatch: The thinnest part of the insulation layer is less than the minimum specified by the standard, or the average thickness is less than the nominal value, creating a risk of failure in service.

Insufficient cross-linking: If the degree of cross-linking doesn’t meet the standard, the heat resistance of the cable is not qualified. It won’t be able to meet the requirement of being able to short-circuit at 250°C under the normal working temperature of 90°C, which will significantly reduce the electrical performance.

Uneven appearance: The thickness of the electric vehicle cable is uneven and the appearance is knotty. Since the cross-sectional area of each segment of the electric vehicle cable is different, the cable will be heated unevenly, which will affect the life of the insulation.

Surface scratches: Normally, electric vehicle cables with surface scratches are eliminated during the testing process and do not appear on the market. However, during transport or installation, the electric vehicle cable may be scratched by foreign objects. It is therefore necessary to check that the insulation of the electric vehicle cable is intact before use.

Lifespan issues: Normal electric wires and electric vehicle cables already in use have a long service life. The insulation resistance of the wire and center head decreases year by year and does not reach the standard value, which also causes quality problems.

Overloading: The electric vehicle cable often runs at full load, and the heat effect of the current causes the center temperature to be too high. The central insulation of the electric vehicle cable is often subjected to rapid temperature changes, frequent temperature changes, large temperature changes, deformed, brittle, and aged due to frequent high-current shock loads or electrical equipment problems.

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