Details
DB communication cable harness is a wiring assembly designed for data communication and signal transmission, combining DB series connectors (such as DB9, DB25, etc.) with high-performance cables. It is widely used in communication equipment, computer networks, industrial automation, and other fields, featuring stable electrical performance and reliable mechanical connections, suitable for high-speed data transmission and long-distance communication needs. Product features include high-purity copper conductors and high-quality shielding layers to effectively reduce signal attenuation and electromagnetic interference, support for various DB connector specifications, customizable pin definitions and wiring sequences, excellent processing craftsmanship with firm solder joints and superior insulation performance, resistance to bending and wear for complex industrial environments, optional EMI/RFI filter components to enhance signal integrity, and compliance with RoHS and REACH environmental standards. Technical specifications: Connector types: DB9, DB15, DB25, DB37, etc.; Cable specifications: AWG22~AWG28, shielded or unshielded; Rated voltage: 300V; Rated current: 1A~5A (depending on wire gauge); Impedance matching: 50Ω, 75Ω, or 100Ω (optional); Operating temperature: -25°C~+85°C; Mating cycles: ≥500 times. Application scenarios: Communication base stations and data center equipment interconnection, industrial PLC control cabinets and sensor signal transmission, medical instruments and test measurement equipment internal connections, computer network and server cabinet wiring, security monitoring system video signal transmission, automated production lines and robot communication systems.
Technical Specifications
| Parameters | Please consult sales for detailed specifications |
| Terminal type | DB9/DB15/DB25 |
| Wire gauge | 28AWG |
| Rated voltage | 300V |
| Rated current | 3A |
| Operating temperature | -40°C ~ +105°C |
| Insulation material | PVC |
Product Features
- High-speed data transmission up to 1Gbps
- Gold-plated terminals, corrosion-resistant with low contact resistance
- Soft harness with bending life over 1 million cycles
- RoHS and UL certified
- Custom lengths and connector configurations
Application Scenarios
- Home Appliances and Consumer Electronics
Custom power cords, signal wires, and ribbon cables meeting ROHS/REACH environmental standards, suitable for white goods and small appliances. - Automotive Electronics and New Energy
Automotive wiring harnesses, sensor harnesses, high-voltage connection harnesses, certified under TS16949 quality system, resistant to high temperature and vibration. - Industrial Automation and Equipment
Robot harnesses, servo motor harnesses, drag chain cables, high flexibility and bending resistance, suitable for complex industrial environments. - Medical Equipment Harnesses
Medical-grade harness customization, biocompatible materials, precision terminal crimping, suitable for monitors, ultrasound equipment, etc.
Frequently Asked Questions
What is the minimum order quantity for custom harnesses?
The MOQ for standard products is 1000pcs, but small trial orders can be as low as 100-200pcs. It is recommended to request samples for quality confirmation for first-time cooperation.
What terminal types and wire gauges are supported?
We support full series terminal crimping (JST/Molex/TE/Hirose, etc.), wire gauges from AWG12 to AWG32, with customizable length, color, and stripping dimensions.
What are the quality inspection standards for harnesses?
We follow UL 486A standards, including continuity testing, insulation withstand voltage testing, pull force testing, and visual inspection, providing full inspection reports with shipments.
Will wire harnesses age after long-term use? How to extend service life?
Under normal operating conditions, this wire harness has a service life of 10~15 years for silicone rubber material and 5~8 years for PVC material. Factors affecting service life: ① Operating temperature — long-term operation at the upper limit of rated temperature will accelerate aging (service life halved); ② Bending frequency — for frequent bending applications, choose high-flexibility wire harnesses (bending life ≥10 million cycles); ③ Environmental factors — UV, ozone, and chemical solvents will accelerate aging of the silicone rubber outer layer. Recommendations to extend service life: leave a 20% margin in operating temperature, avoid contact with chemical solvents, install protective sleeves during fixed wiring, and regularly check whether the terminal crimp area is heating.
What certifications has this wire harness passed? Can certification reports be provided?
This wire harness has passed UL (United States) and CE (European Union) certification and complies with RoHS environmental protection and REACH regulatory requirements. The UL certification number is traceable, and CE declaration documents are complete. For bulk purchases, the following can also be provided: UL certification copy, material certificate (MDS), SGS environmental test report, and product flame retardant test report. For customers with special certification requirements (such as VDE, CCC, PSE, KC, etc.), please inform us in advance, and certification applications can be arranged separately.
How is the wiring harness waterproofed when used outdoors?
The insulation layer of this machine's wiring harness itself is water-resistant (both silicone rubber/PVC do not absorb water), but for outdoor exposed use, it is recommended to combine the following solutions to enhance waterproofing: ① Use IP67/IP68 waterproof connectors; ② Add waterproof heat-shrink tubing (with hot melt adhesive) at the crimp; ③ Cover the cable with a PVC or PE protective sleeve to enhance mechanical protection; ④ Use potting compound (epoxy resin or polyurethane) at the connection to achieve permanent waterproofing. Combined with the above solutions, long-term underwater connection (10 meters water depth) can be achieved, suitable for scenarios such as LED underwater lights, sewage treatment equipment, and marine wiring harnesses.
What is the temperature resistance range of the wire harness? Can it be used long-term in high-temperature environments?
The temperature resistance range of the wire harnesses in this machine varies by insulation material: silicone rubber insulation -60℃~+200℃ (short-term peak 250℃), PVC insulation -20℃~+105℃. In high-temperature environments (such as automotive engine compartments, around industrial furnaces, and inside new energy vehicle battery packs), silicone rubber wire harnesses must be selected; PVC material will accelerate aging and crack the insulation layer in such scenarios. For low-temperature environments (such as extremely cold outdoor areas) and high-low temperature cycling applications, silicone rubber wire harnesses are also recommended.
What is the flame retardant rating of the wire harness? Does it comply with the UL VW-1 standard?
The flame retardant rating of this wire harness reaches UL VW-1 (vertical burn test), which is the minimum flame retardant requirement of the UL 758 electronic wire standard. Higher flame retardant ratings are optional: UL VW-1 + vertical burn, UL FT2 (horizontal burn), UL VW-1 + FT2 dual certification. Significance of flame retardant standards: For a wire harness that passes VW-1, in the vertical burn test, after 5 times of 15-second burning, the flame self-extinguishes within 60 seconds, does not ignite the cotton cloth below, and has no burning drips. For applications with high fire protection requirements (such as inside new energy vehicle battery packs and medical devices), it is recommended to select a wire harness with a higher flame retardant rating.
What is the conductor material of this wire harness? Bare copper or tinned copper?
This product uses stranded tinned copper wire conductors, balancing conductivity and corrosion resistance. Bare copper conductivity is approximately 101%IACS, and tinned copper is approximately 98%IACS (difference only about 3%). Advantages of tinning: oxidation resistance is 3~5 times stronger, solderability is better (avoiding solder non-wetting issues), and corrosion resistance is significantly improved. For scenarios requiring high reliability such as new energy vehicles and outdoor equipment, it is recommended to prioritize tinned copper wire harnesses.
What is the minimum bending radius of the wire harness? Can it be used for wiring in confined spaces?
The minimum bending radius of this wire harness is 5 times the wire diameter, far smaller than the 10 times wire diameter requirement for ordinary PVC wire. Due to the stranded structure of multiple extra-fine tinned copper wires, the harness offers excellent flexibility and can be routed flexibly in confined spaces such as mobile phones, sensors, automotive door panels, and LED luminaires, and repeated bending is unlikely to break the core. If a smaller bending radius is required (such as robot drag chains), a high-flexibility drag-chain-specific wire harness can be selected.
How to judge the quality of wire harnesses?
3 methods to quickly identify wire harness quality: ① Visual inspection — the insulation surface is smooth with no marks, no bubbles, and no color difference or eccentricity; ② Bending test — after repeated bending 100 times, the insulation has no cracks (silicone rubber) and no obvious whitening (PVC); ③ Flame test — for high-quality wire harnesses, self-extinguishing time after removal from flame is ≤30 seconds (UL VW-1/FT2 standard); inferior wire harnesses continue burning with drippings. Also measure insulation thickness (whether it meets UL standard) and conductor resistance (≤ UL specified maximum). Before bulk purchasing, it is recommended to require the supplier to provide samples for comprehensive quality confirmation.
What is the difference between new energy vehicle wire harnesses and ordinary wire harnesses?
New energy vehicle (EV/HEV) wire harnesses must meet higher standards: ① Temperature resistance grade — the internal temperature of the battery pack can reach 85~150℃, so silicone rubber wire harnesses must be selected (PVC cannot meet the requirement); ② Voltage resistance grade — high-voltage connection wire harnesses withstand 600V~1000V, far higher than ordinary 300V; ③ EMC shielding — high-voltage wire harnesses require an added braided shielding layer to prevent electromagnetic interference (EMC, compliant with CISPR 25 standard); ④ Flame retardant requirements — VW-1 + low smoke zero halogen (LSZH); ⑤ Vibration resistance — terminal crimping must not loosen under high-frequency vibration environments (vehicle operation); ⑥ TS16949 automotive quality management system certification. Ordinary wire harnesses do not meet the above requirements and are prohibited for use on new energy vehicles.
About Winna Technology
Winna Technology specializes in power adapters, AC/DC cable harness customization, and ultrasonic metal welding equipment R&D and manufacturing, providing one-stop OEM/ODM services.
Our products are CE/UL/FCC/CCC/RoHS certified, with an annual return rate below 0.02%, serving customers in 50+ countries and regions worldwide.
