Overview of Common Issues with Electric Car Cables

Electric Car Cables Wear and Damage Issues

Outer Sheath Wear

Prolonged friction, dragging, bending, or scraping may lead to the electric car cable sheath getting worn out. This kind of wear can expose internal wires, increasing the risk of short circuits and electric shocks.

Interface Damage

Frequent plugging and unplugging, improper handling, or mechanical impacts may cause damage to the electric car cable at the charging gun interface or the charging pile interface. Common issues include bent or broken pins and poor contact.

Electric Car Cable Overheating Issues

Excessive Current

Choosing an inappropriate electric car cable specification may lead to insufficient current carrying capacity, resulting in overheating.

Mismatched Wire Gauge

Thin wire gauge or poor-quality cables can result in high resistance, generating excessive heat during prolonged high-current charging.

Poor Heat Dissipation

Electric car cable arrangements that are too dense, poorly ventilated, or subjected to high external temperatures can affect the cable's heat dissipation.

Electric Car Cable Moisture Intrusion Issues

Seal Failure

Aging or damage to seals at the charging gun interface and cable connectors can allow rainwater and moisture to enter the cable, leading to decreased insulation and potential short circuits.

Environmental Impact

Using electric car cables in humid, rainy or water-laden environments or submerging cables in water can lead to moisture penetration.

Electric Car Cable Electrical Fault Issues

Poor Insulation

Electric car cable insulation material aging or damage can cause short circuits between wires or ground leakage.

Loose Connections

Loose connections at cable joints can increase contact resistance, leading to severe heating.

Control Signal Anomalies

For communication-enabled electric car cables, signal transmission faults can cause charging interruptions or failure to start.

Electric Car Cable Improper Installation and Use Issues

Inappropriate Cable Length

Electric car cables that are too long or too short can affect usability and may lead to excessive voltage drops, reducing charging efficiency.

Unsecured Cable Fixing

Cables that are laid out haphazardly or without proper fixing are prone to external forces pulling or wearing them.

Incorrect Cable Selection

Not selecting the appropriate cable specifications according to charging pile power or vehicle charging requirements may result in low charging efficiency or safety hazards. Choose compliant electric car cables to ensure the normal operation of the charging system.

Environmental and Quality Issues of Electric Car Cables

UV Aging

Outdoor electric car cables that are exposed to sunlight for extended periods may undergo aging and embrittlement of the sheath material.

Chemical Corrosion

Contact with oil, acid, alkali, and other corrosive substances can affect the cable's insulation and mechanical performance.

Animal Bites

In some environments, animals may gnaw through the cable sheath.

These common issues with electric car cables can be effectively prevented and resolved through regular inspection and maintenance. For complex issues, it is recommended to seek the help of professional technicians to ensure the safe and efficient operation of the charging system.