The core of aging test data for new energy storage wiring harnesses lies in simulating actual usage scenarios and observing the long-term operational changes in the state of key components of the harness, rather than relying on fixed numerical values. During testing, the harness is subjected to environmental conditions similar to those encountered in daily energy storage system operation, including repeated high and low temperature cycles, constant humidity fluctuations, and vibrations simulating equipment operation. This recreates the actual aging stresses the harness may face. In this simulated environment, personnel focus on whether the harness insulation shows signs of damage, cracking, or adhesion, whether the conductors show signs of oxidation or corrosion, and whether the connections remain secure. These intuitive status feedback constitutes the core of the aging test data and directly reflects the harness's ability to withstand aging.
As a key protective structure of the new energy storage wiring harness, its aging resistance is a key component of aging test data. Since the harness may be exposed to significant temperature fluctuations during energy storage system operation, insufficient aging resistance will gradually lose its protective properties, increasing the risk of system short circuits. Therefore, during testing, the physical condition of the insulation layer is continuously monitored to see whether it maintains its original flexibility and integrity despite environmental changes. Professional methods are also used to determine the stability of its insulation performance. If the insulation layer remains intact and the insulation performance does not show a significant decline, the wiring harness is relatively reliable in terms of insulation aging. Otherwise, further evaluation is required to determine whether it can meet the requirements of long-term use.
Conductor performance stability is also a crucial aspect of aging test data. The conductors of new energy storage wiring harnesses carry the important task of current transmission. Over long-term use, if the conductors are exposed to environmental factors such as moisture and dust, oxidation or corrosion will directly affect the conductive efficiency. During aging testing, environments that may damage the conductors are simulated. After a period of time, the conductor surface is observed to ensure it remains smooth and free of rust or oxide layers. The conductors are also checked to ensure that their conductivity remains at normal levels. These observations clearly demonstrate the conductor's resistance to aging and provide important evidence for assessing the overall aging performance of the wiring harness.
Wiring harness connections, such as the connection between terminals and wires, are key details to focus on during burn-in testing, and their condition is also a crucial component of the test data. Due to long-term exposure to temperature fluctuations and vibration, connections are prone to loosening or poor contact, which can cause localized heating and accelerate harness aging. During testing, we closely monitor connections for signs of looseness, oxidation, or heat buildup. If connections remain secure and show no obvious abnormalities in the simulated aging environment, the harness demonstrates good connection stability and can ensure safe current transmission during long-term use.
The performance degradation rate of new energy storage wiring harnesses after long-term use is not determined by a single standard but rather relies on a combination of raw material selection, production processes, and protective design. In terms of raw materials, selecting conductors and insulation materials with enhanced aging resistance can slow down the aging of wiring harnesses.
During the production process, rigorous crimping processes ensure the stability of connections and reduce premature degradation caused by process defects. Comprehensive sealing processes protect the internal structure from external environmental damage. Furthermore, rational wiring and fixing designs can reduce the damage caused by equipment vibration. These factors work together to control the performance degradation rate within an industry-recognized range, ensuring that the wiring harness functions properly within its designed lifecycle.
The effectiveness of controlling the performance degradation rate must be comprehensively assessed based on the specific usage scenario and design life of the energy storage system. Energy storage systems in different scenarios have different requirements for wiring harness aging. For example, wiring harnesses in outdoor energy storage systems must withstand harsher temperature and humidity environments, and
Their performance degradation control standards are more stringent than those in indoor systems. Energy storage systems with longer design lifespans also require higher long-term wiring harness degradation resistance. Therefore, the key to determining whether a wiring harness's performance degradation rate meets acceptable standards lies in determining whether, within the specified scenario and design lifespan, its performance degradation remains within a range that does not affect the safe and stable operation of the system. Rather than pursuing a uniform degradation level standard, as long as the wiring harness maintains stable performance under specific operating conditions, its degradation rate control meets the required performance.
Industry standard certification also indirectly reflects the reliability of the new energy storage wiring harness's aging test data and the level of performance degradation control. Wiring harnesses that have passed relevant industry standard certifications indicate that their aging test procedures and performance degradation control measures have been reviewed by authoritative organizations and comply with generally recognized industry standards. During aging tests, the performance of key components of such wiring harnesses is more likely to meet long-term operating requirements, and the performance degradation rate is consistently controlled within a reasonable range. Therefore, monitoring a wiring harness's compliance certification is an important reference for assessing its aging test performance and degradation control capabilities. This allows for a clear understanding of its long-term reliability without relying on specific data.
