Causes of Common Electric Vehicle Cables Problems

Causes of Common Electric Vehicle Cables Problems

The quality of electric vehicle cables directly affects the safe operation of the line. Once the line cannot operate safely and stably, the unpredictable losses caused by the failure to life and economy are inevitable. Therefore, when choosing electric vehicle cables, it is important to choose a reliable brand. The common problems in the use of electric vehicle cables are generally caused by two reasons. One is the use of inferior electric vehicle cables, which have significant problems in production, and the other is improper use or maintenance of electric vehicle cables. What are the common reasons for problems with electric vehicle cables?

Understanding electric vehicle cables

Electric vehicle cables are carriers that connect electric vehicles and charging piles, and their basic function is to transfer electric energy. However, with the development of charging technology, in order to better complete the charging process, good communication should be established between electric vehicles and charging piles, and automatic adjustment should be made if necessary. Therefore, the charging process imposes higher requirements on the charging cable. The charging cable not only needs to have the function of transmitting electricity, but also needs to transmit the status and information of the car and power battery to the charging pile for real-time interaction. If necessary, the charging response should be adjusted to safely and reliably complete the charging process.

What are the common reasons for problems with electric vehicle cables?

  • Unqualified structure. The thinnest point of the insulation layer is lower than the minimum value specified by the standard, or the average thickness is lower than the nominal value, and there is a risk of breakdown when used.

  • Unqualified cross-linking degree. If the cross-linking degree fails to meet the standard, the cable's heat resistance is unqualified, and it cannot meet the requirement of allowing a short circuit of 250℃ under normal work temperature of 90℃, which greatly reduces the electrical performance.

  • Bamboo-like appearance. The thickness of the electric vehicle cable is uneven, and the appearance of the electric vehicle cable is bamboo-like. Due to the different cross-sectional areas of each section of the electric vehicle cable, the heating of the electric vehicle cable is uneven, which affects the insulation life.

  • Surface scratches. Under normal circumstances, electric vehicle cables with surface scratches will be eliminated during the testing process and will not be on the market. However, electric vehicle cables may still be scratched by foreign objects during transportation or laying. Therefore, before use, the insulation of electric vehicle cables must be checked for integrity. Normal electric wires and electric vehicle cables that have been put into operation have a long service life and have reached the end of their service life. The insulation resistance of the electric wire and the insulation resistance of the center head decrease year by year and cannot reach the standard value, which can also cause quality problems.

  • Electric vehicle cables often operate at full load, which leads to the center temperature being too high due to the thermal effect of the current. The center insulation of the electric vehicle cable deteriorates often due to frequent large current shock load or problems with electrical equipment, resulting in cold and hot center insulation, frequent temperature changes, and large temperature differences, causing the insulation to deform and become brittle and the center insulation to deteriorate.

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