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.