Connector heating

A DC fast-charging connector rated for hundreds of amps on day one isn't the same connector a few thousand mating cycles later.

It doesn't fail all at once. It degrades quietly — a little more contact resistance with every plug-in, a little more heat under the same load, until one day it isn't reliable anymore.

That failure curve is well understood in high-voltage connector engineering. It's rarely talked about in terms of what it actually means for a charging network's day-to-day reliability — or what the qualification standard really requires a connector to survive before it ever reaches the field.

We wrote up the physics behind it, the testing standard behind it, and what it means for anyone specifying or operating high-power charging hardware, in "Connector Heating" — the third piece in our series on cable and connector reliability.

Download it at www.kemplink.com and read the full piece.

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