What are the effects of excessive bending on car charging cables

As electric vehicles gradually become mainstream transportation, the stability and safety of the performance of car charging cables, as an important connection medium between electric vehicles and charging facilities, are increasingly valued. However, many car owners and charging station managers often ignore the impact of the bending degree of the cable on its overall performance in actual operation, resulting in damage to the cable due to excessive bending, which directly affects the charging efficiency and safety.

Relationship between cable structure and bending effect
The structure of the car charging cable is usually composed of key parts such as conductor, insulation layer, shielding layer and outer sheath. The conductor is responsible for the transmission of current, the insulation layer is used to isolate the conductor from the external environment, the shielding layer effectively suppresses electromagnetic interference, and the outer sheath provides additional protection and wear resistance. If the cable is excessively bent during use, its various components may be damaged to varying degrees, which not only affects the function of the cable, but also may cause potential safety hazards.

Decrease in signal quality and transmission efficiency
Over-bent cables will exert excessive force on the internal conductor and change its signal transmission characteristics. This change may cause signal loss and interference, resulting in equipment failure or signal quality degradation. For car charging cables, the decline in signal quality will directly affect the charging efficiency. When the bending degree is too large, the transmission path of the current in the conductor will change, resulting in increased resistance, which will affect the charging speed and stability, and then affect the user experience.

Cable damage and safety hazards
Excessive bending of the cable will not only cause the outer skin to loosen or break, but also may cause the conductor to be squeezed and worn. Long-term squeezing and wear will gradually break the conductor, and eventually lead to cable failure. In addition, the insulation layer of the cable is also easily damaged in the case of excessive bending, which may cause the current to leak into the external environment, causing problems such as short circuits and overheating. In extreme cases, these problems may even cause serious safety hazards such as fire.

Cable life and aging issues
Excessively bent cables will not only affect charging efficiency and safety, but also cause excessive internal stress in the cable, accelerating the aging process of the cable. The aging of the cable involves oxidation, degradation and degradation of the material's mechanical properties. When the cable is subjected to excessive bending, its internal stress distribution will change significantly, making the material more susceptible to oxidation and degradation. This accelerated aging process will significantly shorten the service life of the cable, increase the frequency of replacement and repair, and bring additional economic burden to users.

Industry standards and minimum bending radius
In order to regulate the use and management of cables, international cable standards (such as ANSI/TIA-568) clearly stipulate the minimum bending radius of various types of cables. These standards are designed to ensure the safety and performance stability of cables in actual use. For automotive charging cables, following the minimum bending radius specified by industry standards is not only a necessary condition to ensure the normal use of cables, but also an important measure to meet the safety requirements of installation and use.