Keywords：LiFePO4 cycle life, connection design, lithium battery degradation
Even high-quality LiFePO₄ cells can lose lifespan quickly if the connection design is poor.
1. Uneven Current Flow Causes Localized Stress
If one connector has higher resistance:
- It heats faster
- Cells near it experience higher load
- Chemical aging speeds up
2. Repeated Overcurrent Due to Wiring Errors
Wrong connection size may trigger:
- Overcurrent cycling
- BMS cutoffs
- SOC imbalance
These accelerate degradation.
3. Mechanical Vibration Loosens Terminals
Loose terminals create arcing, which damages:
- Electrodes
- Terminal posts
- BMS MOSFETs
Industrial ESS cabinets must use anti-vibration washers.
4. Long-Term Impact
Poor connections reduce:
- Usable capacity
- Peak discharge capability
- Energy throughput
Proper wiring can increase cycle life by 20–30% in long-term systems.