Analysis Of Poor Contact In Bimetallic Terminals Due To Improper Handling Of Wire Ends

In many electrical connection systems, poor contact can easily occur if the contact surface of the bimetallic lugs terminal is not properly treated.

If the exposed wire core is not neatly trimmed after stripping, or if there are forked cores or residual insulation, the wire core may not be able to fully enter the blind hole of the bi metal cable lug terminal. If the screw is tightened before the wire core is fully inserted, part of the wire will be trapped between the screw and the terminal by the insulation layer, significantly reducing the actual contact area. Even if tightened, the connection may appear secure, but high resistance, intermittent connections, or even overheating may occur.

Furthermore, burrs, damage, or oxidation residue on the wire core edges can cause a rough and uneven metal contact surface, resulting in uneven contact pressure distribution. If the internal metal parts of the bi metal lugs connectors terminal are oxidized or contaminated, and the wire end is inserted directly without cleaning, the probability of poor contact is further increased.