Detailed Guide to Battery Terminals: Definition, Types, Selection, and Installation
Definition and Purpose of Battery Terminals
Battery terminals are critical components that connect batteries to external conductors, primarily used for transmitting electrical signals or conducting electricity. In electrical engineering, terminals generally refer to wiring endpoints, with types including single-hole, double-hole, plug-in, and hook terminals. Materials commonly include silver-plated copper, zinc-plated copper, copper, aluminum, or iron. Tubular wiring terminals (also known as tubular crimp connectors) are commonly used conductive accessories in battery connections, belonging to the category of crimp terminals and industrially classified as connectors.
Common Types and Specifications of Battery Terminals
General-Purpose Terminals (UK/NT Series):
Pitch: 5.0mm/5.08mm/7.62mm
Suitable wire gauge: 0.2-6mm²
Current range: 10-32A
Typical applications: PLC control cabinet signal wiring, sensor connections
High-Current Terminals (H/HD Series):
Pitch: 10.16mm/15mm
Conductor cross-section: 16-300mm²
Current range: 80-500A
Typical applications: PV inverter DC side, energy storage battery pack busbars
Barrier Terminals (TB/JB Series):
Barrier height: 8-15mm (finger-safe design)
Wiring aperture: Φ3.5-Φ8mm
Protection rating: IP20 (basic type)/IP65 (waterproof type)
Typical applications: Motor terminal boxes, outdoor distribution boxes
Spring-Cage Terminals (PUSH-IN Series):
Insertion depth: ≥8mm
Wire compatibility: 0.14-4mm² (tool-free crimping)
Width: 5.2mm (high-density installation)
Typical applications: Building automation, lighting control systems
Key Considerations for Battery Terminal Selection
Current and Voltage Requirements:
Select products with ratings matching system requirements to avoid overload or voltage mismatch
Power selection based on load current and voltage, with safety margin
Material Compatibility:
Ensure terminal material is compatible with cables used (e.g., avoid electrochemical corrosion when connecting copper wires)
Plastic components should have good flame retardancy (self-extinguishing when removed from open flame)
Wire Cross-Section Matching:
Choose terminal wiring range slightly larger than actual wire diameter to avoid insertion issues due to standard variations
Compatibility with multiple cross-sections (e.g., 1.5mm², 2.5mm²) improves installation efficiency
Installation Method:
DIN rail mounting has become the mainstream standard in industrial control fields
Select smaller terminals for confined spaces, with appropriate fixation methods
Safety Certifications:
Prioritize products certified with CE, RoHS, UL, etc.
Appearance should be smooth without deformation, scratches, burrs, and with uniform thickness
Environmental Adaptability:
Select high-temperature resistant materials for high-temperature environments
Choose materials with good sealing and moisture resistance for high-humidity environments
Use acid and alkali corrosion-resistant materials for chemical environments.
Battery Terminal Installation Precautions
Safety Preparations:
Wear protective gloves and safety goggles
Use insulated tools to prevent metal tools from simultaneously contacting positive and negative terminals
Turn off power before installation to ensure a safe operating environment
Connection Process:
Remove oxidation from cable ends to ensure secure connections
Connect in positive-to-negative sequence (connect positive terminal first, then negative terminal)
Apply force evenly, with the force application point on the battery casing to prevent terminal damage
Multiple Battery Parallel Connection:
Arrange according to "+" "-" polarity sequence
Maintain spacing of no less than 15 mm
Secure connection points to avoid sparks and poor contact
Post-Installation Inspection:
Check if screws are properly tightened
Test whether connections are normal
Inspect battery appearance and fixing devices
Special Environment Considerations:
High-temperature environments: Select heat-resistant materials
High-humidity environments: Ensure sealing performance
Vibration environments: Choose connection methods with good anti-vibration performance