Why Does the Charging Cable Heat Up During New Energy Vehicle Charging?
2 Answers
There are several reasons why the charging cable may heat up during new energy vehicle charging: Short Circuit: During a short circuit, the current in the circuit can increase several to dozens of times, rapidly generating a large amount of heat. This heat can immediately burn through the conductor's insulation; if the heat spreads to nearby flammable materials, it may cause a fire. Overload Charging: Improper selection of wires and equipment during design or exceeding the rated current capacity can cause the equipment to overheat due to overload. Poor Contact: Loose wire connections, poor contact in movable contacts, or electrolytic corrosion in copper-aluminum connections can all lead to overheating. Poor Heat Dissipation: Charging piles generally have certain heat dissipation or ventilation measures. If these measures are compromised, it may result in equipment overheating.
Last time I charged my electric car, the cable got extremely hot. At first, I thought it was just because of the summer heat, but later I realized this is actually quite common. The main reasons for cable heating are the high current during charging, combined with poor cable quality or aging, which increases resistance and generates more heat. After experiencing this a few times, I started paying attention. Now I always check the cable for any damage and make sure the connections are tight before charging. I also ensure good ventilation and avoid charging under direct sunlight. These days, I only use the original charging cable and limit fast charging time, as excessive heat can damage the insulation and potentially cause a fire. Developing good habits is key—safety first. Don't take risks just to save time.
