Creepage Problems Caused By Burrs On The Surface Of Cable Terminals

When burrs are present on the cable lugs surface, these irregular small protrusions provide local paths for leakage current along the surface. In humid, polluted, or drastically temperature-changing environments, conductive contaminants are more likely to accumulate in the gaps between microcracks and burrs, lowering the voltage threshold required along the wire lugs insulation surface and triggering leakage current along the surface.

During manufacturing, the precision of stamping or die processing directly affects the edge quality of the electrical lugs. Improper production equipment parameters, die wear, or low raw material hardness can all lead to burr formation and embedding in the terminal lugs edge. These geometric defects not only affect the fit accuracy but also alter the actual electric field distribution between the copper lugs and the insulator, increasing the local electric field strength and promoting charge diffusion along the defective surface.