Battery Systems Cabling & Wiring: Selection, Termination, and Verification

Wire

Typically a single conductor with insulation used to carry electric current.

Cable

An assembly of one or more insulated conductors designed for mechanical protection and flexibility.

Conductor

The metal path that electrons move through to carry current.

Copper

A conductor material known for high conductivity and good flexibility, widely used in battery packs.

Aluminum

A lighter, cheaper conductor material but with higher resistance than copper.

Solid conductor

A single solid piece of metal that holds shape well but fatigues more easily with vibration.

Stranded conductor

Many small strands bundled together, preferred for its flexibility and vibration resistance.

Insulation

Material that prevents unintended contact between conductors or between a conductor and chassis/ground.

Jacket

An outer protective layer that safeguards insulation from abrasion, fluids, and heat.

Voltage rating

The maximum electric field that a wire or cable can withstand without breakdown.

Temperature rating

The maximum temperature that a wire or cable can safely handle continuously.

Abrasion resistance

The ability of a wire or cable to withstand wear and tear when routed through enclosures or around brackets.

AWG

American Wire Gauge, a standard for measuring wire size.

V_{ ext{drop}}

The voltage drop across a wire due to its resistance when a current flows through it.

P_{ ext{loss}}

The power dissipated as heat in a wire, represented as $I^2R$.

Twisted pair

A pair of insulated conductors twisted together to cancel induced noise from external electromagnetic fields.

Shielded cable

Cable with a conductive layer that reduces electromagnetic interference (EMI).

Coaxial cable

Cable with a central conductor, dielectric insulation, and an outer shield conductor, used for high-frequency signals.

Terminal block

A connection point for wires that allows removal and re-landing without cutting.

Crimped butt splice

A method of joining conductors by compressing a connector barrel around the conductor using a crimp tool.

Soldered splice

Joining conductors with a molten filler alloy, used for its low electrical resistance.

Insulation displacement connectors (IDC)

Connectors that cut through insulation to contact the conductor, commonly used in low-current applications.

Resistance measurement

A method to test and identify high-resistance joints in conductors.

Insulation resistance testing

Testing that measures how well insulation prevents leakage between conductors or from conductor to ground.

Polarity verification

Ensuring that the wiring harness is connected to the correct pins to avoid reverse connections.

Voltage drop testing

Measuring the voltage across a cable segment while current is flowing to evaluate its performance.

Intermittent fault testing

Testing for faults that only appear when the harness is moved or vibrated.