In daily electrical equipment maintenance, copper flexible links are often the most overlooked yet critical components. Many users are unsure about when these connectors need to be replaced. In fact, by observing certain everyday signs, potential issues can be detected in a timely manner.
Copper flexible connectors gradually change during use, and the most intuitive way to assess their condition is by observing their appearance. Under normal circumstances, the surface of the copper wire should maintain its metallic luster or have an intact coating. If extensive oxidation blackening, coating peeling, or green rust corrosion is observed, it indicates a decline in its protective performance. Particularly when dark brown oxidation patches appear at the connection terminals, it often signifies an increase in contact resistance. Additionally, if the flexible connector bundle shows broken strands, deformation, or loosening, it suggests that its mechanical strength may no longer meet safety requirements.
Temperature performance during operation is another important indicator. Under the same load conditions, if the temperature at the connection point is significantly higher than before, or if there is an excessive temperature difference among multiple connection points in the same equipment, it usually indicates aging in some of the connection points. Particularly during load fluctuations, an increased range of temperature changes is a signal that requires attention. In some cases, a distinct odor from overheated insulation materials may also be noticeable, which should not be ignored as a warning sign.
Changes in equipment operating conditions can also reflect the state of the flexible connectors. When the system experiences increased voltage fluctuations, abnormal noises, or enhanced vibrations, after ruling out other factors, it is advisable to check whether the flexible connectors have become loose or are making poor contact. For critical circuits, regularly measuring the trend in circuit resistance values can provide a more accurate assessment of the health of the flexible connectors. If the resistance value shows a continuous upward trend, even if no obvious external abnormalities are observed, preventive replacement should be considered.
The inspection frequency varies depending on the application environment. For general industrial environments, a comprehensive inspection every six months is recommended. However, in high-temperature, high-humidity, or corrosive gas environments, the inspection frequency should be appropriately increased. It is important to note that when replacing connectors, not only should products with the same specifications as the original be selected, but it is also crucial to ensure that the installation process complies with standards. Proper crimping force, appropriate bending radius, and standardized bolt torque are all key factors in ensuring the service life of the new flexible connectors.
