Analysis Of Potential Heat Generation And Short Circuit Risks Of Copper Terminal Blocks

Within the copper terminal block circuit, poor contact between the conductor and terminal can lead to high contact resistance. Current flowing through poor contact points generates Joule heating. As heat accumulates, the terminal temperature rises continuously, potentially causing oxidation, softening, and even red-hot discoloration of the conductor and terminal surfaces. If the temperature continues to rise, it can damage the insulation structure, causing short circuits or arcing, and ultimately, a fire.

Poor contact is prone to occur when the copper conductor or its connection to the terminal is not tightened, the connection is loose, or an unsuitable wire gauge is used. Over time, vibration and temperature changes exacerbate this loosening. Reduced contact area, increased resistance, and heat concentration at the connection point create a "high-resistance contact" that easily becomes a heat source.

If the working environment is humid, contains corrosive gases or dust, an oxide layer or contaminants may form on the terminal surface, all of which can increase contact resistance. In such environments, the reliability and safety of the copper distribution block circuit will be severely affected.

To mitigate these risks, it is recommended to perform torque checks at each connection point during installation or maintenance of the copper terminal strip circuit to ensure a tight fit between the conductor and terminal. For locations susceptible to moisture or corrosion, protective measures should be considered, and the terminal condition should be checked regularly. For circuits with high current carrying capacity, connectors matching the conductor wire diameter should be selected, and operation beyond the rated current should be avoided to reduce the probability of overheating and short circuits.