Analysis And Detection Of Internal Defects In Cable Terminals

electrical lugs Geometric and material anomalies in the internal metal contact area may cause abnormal contact impedance. The structural inconsistency of terminal lugs may originate from uneven material distribution during the production process or microcracks introduced by the stress of the pressing process, which may cause the contact path to exhibit high resistance or unstable conduction.

Tiny voids or impurities inside the insulator of copper lugs alter the electric field distribution characteristics, and these distorted electric field regions become local charge accumulation points. Under high voltage or pulsed conditions, this can accelerate dielectric breakdown, leading to partial discharge or insulation degradation.

Aluminum Cable Lug Minor misalignments and loose fits in mechanical mating areas are another common source of problems. Mechanical instability at the conductor-terminal junction is exacerbated by the cumulative effects of vibration and thermal cycling, frequently occurring in automotive and industrial equipment applications.