Details
The automotive LED headlight wiring harness is a high-performance connection component designed for modern automotive headlight systems. It uses high-quality heat-resistant insulation materials, combined with precision terminals and connectors, to ensure stable power and signal transmission in harsh environments such as high temperature and vibration. This harness is widely used in the headlight assemblies of various passenger cars and commercial vehicles, representing a mature solution in the automotive wiring harness processing field. Product Features: Excellent Heat Resistance: Uses special insulation materials with a temperature rating above 125°C, suitable for the high-temperature environment of the engine compartment. Excellent Insulation Performance: Insulation resistance ≥100MΩ, effectively preventing leakage and short circuit risks. High-Reliability Connection: Equipped with gold-plated or tin-plated terminals, low contact resistance, resistant to vibration loosening. Customized Design: Can provide different lengths, terminal types, and sheath solutions according to customer drawings. Strict Quality Control: Full process includes continuity testing and insulation withstand voltage testing to ensure zero-defect delivery. Technical Parameters: Rated Voltage: DC 12V / 24V; Rated Current: Supports 5A-20A depending on wire gauge; Operating Temperature Range: -40°C to +125°C; Insulation Material: PVC / XLPE / Silicone (optional); Terminal Material: Brass tin-plated / Phosphor bronze gold-plated; Protection Level: IP67 (optional waterproof sheath). Application Scenarios: The automotive LED headlight wiring harness is mainly suitable for: Passenger car headlights (high beam, low beam, daytime running lights); Commercial vehicle/truck LED headlight systems; Modified vehicle lights and auxiliary lighting groups; New energy vehicle headlight assemblies. This harness can be used with various LED modules and drivers, and is a common standardized component in automotive wiring harness processing.
Technical Specifications
| Parameters | Please consult sales for detailed specifications |
Product Features
- Please contact sales for detailed product features
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?
What terminal types and wire gauges are supported?
What are the quality inspection standards for the harnesses?
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.
Wire Harness Customization & Processing Flow
From requirement confirmation to finished product delivery, 10 processes with strict checks at every stage ensure each wire harness meets the highest quality standards
We have comprehensive wire harness customization and processing capabilities, covering the entire process from requirement confirmation to finished product delivery. The following is the standard wire harness processing workflow, with strict quality control standards at each step to ensure product consistency and reliability.
Confirm Requirements, Start with Precision
Before production, engineering confirms the specifications based on the customer's drawings and specifications. Any pending items are communicated with the customer to resolve production questions before finalizing the manufacturing process, ensuring every step is accurate.
Cutting Precision Down to the Millimeter
Cut wires (cables) to the required length and coil them. Operators carefully verify the specifications on the production work order before cutting, using calibrated advanced equipment to ensure the processing quality of each wire.
Professional Stripping, Precision Pre-Soldering
Remove the wire jacket (outer sheath) and any unnecessary fillers. Use a professional pneumatic wire stripper to strip the jacket, then perform pre-soldering. Adjust the equipment precisely according to each wire specification to ensure zero damage to the core conductor.
Secure Connection, Reliable Transmission
Crimp the terminal to the wire (cable) core conductor. Use a professional terminal crimping machine, with dedicated crimping dies for different terminals. Strictly adjust the machine and check the crimping specifications before operation to ensure each terminal connection is firm and reliable.
Fine Assembly, Quality Assurance
According to the engineering drawing, sort the crimped core wires, assemble them into the connector housing, and reinforce the wire harness strength. All processing methods strictly follow the engineering drawing and SOP, using specialized tools to ensure consistency.
Full Traceability at a Glance
Attach labels containing information such as specifications, ID, and serial number to each customized wire. Labels help assembly personnel quickly find the corresponding interface and facilitate future traceability of production history, enabling full-process digital management.
Self-Inspection & Peer Check, Layered Control
After assembly, perform self-inspection during wire harness production based on the production work order drawings and dimensions, ensuring all manufacturing details are confirmed. Every step is recorded, and every link is traceable.
Four-Wire Testing, Zero Defects Outgoing
All completed wire harnesses undergo continuity testing, resistance measurement, wire position measurement, and insulation resistance testing using a four-wire electrical tester. They are only released after confirming normal electrical characteristics, ensuring each wire harness meets design standards.
Digital Archiving, Traceable Quality
Record and archive images of the finished wire harness. Production engineering data and appearance are digitally archived for easy future review, modification, or addition. Digital management ensures precise reproduction of wire harnesses with the same specifications.
Safe Protection, On-Time Delivery
Carefully package with cushioning materials to ensure no damage during transportation, and ship according to the specified method. Full tracking from packaging to logistics ensures products are delivered safely and on time to the customer.
Need Wire Harness Customization Services?
From solution design to mass production, Winna Technology provides one-stop wire harness customization solutions
Contact for Customization →Specifications
Wire Harness Customization & Processing Flow
From requirement confirmation to finished product delivery, 10 processes with strict checks at every stage ensure each wire harness meets the highest quality standards
We have comprehensive wire harness customization and processing capabilities, covering the entire process from requirement confirmation to finished product delivery. The following is the standard wire harness processing workflow, with strict quality control standards at each step to ensure product consistency and reliability.
Confirm Requirements, Start with Precision
Before production, engineering confirms the specifications based on the customer's drawings and specifications. Any pending items are communicated with the customer to resolve production questions before finalizing the manufacturing process, ensuring every step is accurate.
Cutting Precision Down to the Millimeter
Cut wires (cables) to the required length and coil them. Operators carefully verify the specifications on the production work order before cutting, using calibrated advanced equipment to ensure the processing quality of each wire.
Professional Stripping, Precision Pre-Soldering
Remove the wire jacket (outer sheath) and any unnecessary fillers. Use a professional pneumatic wire stripper to strip the jacket, then perform pre-soldering. Adjust the equipment precisely according to each wire specification to ensure zero damage to the core conductor.
Secure Connection, Reliable Transmission
Crimp the terminal to the wire (cable) core conductor. Use a professional terminal crimping machine, with dedicated crimping dies for different terminals. Strictly adjust the machine and check the crimping specifications before operation to ensure each terminal connection is firm and reliable.
Fine Assembly, Quality Assurance
According to the engineering drawing, sort the crimped core wires, assemble them into the connector housing, and reinforce the wire harness strength. All processing methods strictly follow the engineering drawing and SOP, using specialized tools to ensure consistency.
Full Traceability at a Glance
Attach labels containing information such as specifications, ID, and serial number to each customized wire. Labels help assembly personnel quickly find the corresponding interface and facilitate future traceability of production history, enabling full-process digital management.
Self-Inspection & Peer Check, Layered Control
After assembly, perform self-inspection during wire harness production based on the production work order drawings and dimensions, ensuring all manufacturing details are confirmed. Every step is recorded, and every link is traceable.
Four-Wire Testing, Zero Defects Outgoing
All completed wire harnesses undergo continuity testing, resistance measurement, wire position measurement, and insulation resistance testing using a four-wire electrical tester. They are only released after confirming normal electrical characteristics, ensuring each wire harness meets design standards.
Digital Archiving, Traceable Quality
Record and archive images of the finished wire harness. Production engineering data and appearance are digitally archived for easy future review, modification, or addition. Digital management ensures precise reproduction of wire harnesses with the same specifications.
Safe Protection, On-Time Delivery
Carefully package with cushioning materials to ensure no damage during transportation, and ship according to the specified method. Full tracking from packaging to logistics ensures products are delivered safely and on time to the customer.
Need Wire Harness Customization Services?
From solution design to mass production, Winna Technology provides one-stop wire harness customization solutions
Contact for Customization →
