What is a temperature rise tester? What is its function?
What is a temperature rise tester? What is its function?
A temperature rise tester is a testing device used to assess whether wires and terminals will exceed safe operating limits due to resistance heating after being energized. It applies the rated or maximum operating current to the tested wire and continuously measures the temperature changes of conductors, terminal crimping points, and connector contacts. This confirms whether the product will experience insulation aging, melting, deformation, or short circuits due to heat during prolonged operation. Temperature rise testing is particularly effective in revealing problems such as insufficient conductor diameter, high crimping impedance, poor terminal contact, or inappropriate material selection, making it a core method for ensuring electrical safety and reliability.
All wires that carry current and have power output require temperature rise testing, including power cords (AC/DC), high-current harnesses, server power module cables, automotive power cords, battery cables, motor drive cables, charging cables, and any harnesses that must comply with UL, IEC, or automotive standards. These wires will generate heat due to resistance during operation; improper design can lead to abnormal temperature rises, increasing failure and safety risks. In contrast, cables used only for low-current or signal transmission typically do not require temperature rise testing.
In short, a temperature rise tester is a device used to confirm whether a cable will overheat after being powered on. Any cable that carries current and may generate heat due to impedance must undergo temperature rise testing to ensure safety and long-term reliability.
