Details
AC/DC wire harness is a customized connection component designed for power equipment, using UL-certified wires, supporting a current range of 5A-30A. The core value lies in providing highly reliable power transmission solutions, compatible with various industrial and consumer electronic application scenarios.
Technical Specifications
| Parameter Name | Technical Specifications / Customization Range |
| Rated Voltage | AC 100V–277V / DC 12V–48V (customizable up to 600V) |
| Rated Current | 1A–15A (expandable to 30A depending on wire diameter and terminal configuration) |
| Conductor Specification | AWG 18–12 Tinned Copper Stranded Wire (customizable AWG 24–10) |
| Insulation Material | PVC / TPE / XLPE (temperature resistance -20°C to +105°C, optional flame retardant VW-1 rating) |
| Connector Type | IEC 60320 C5/C7/C13/C14 / Customer-defined terminals (crimping/injection molding) |
| Shielding Structure | Unshielded / Aluminum Foil Shield / Braided Shield (coverage ≥85%) |
| Harness Length | 0.3m–5.0m (tolerance ±5%, can be customized to millimeter precision per customer requirements) |
| Withstanding Voltage Test | AC 1500V / 1 minute (no breakdown, leakage current ≤5mA) |
| Environmental Compliance | RoHS / REACH / UL Certification (assistance with UL file listing available) |
| Custom Identification | Wire printing / Labels / Color rings / Packaging method (according to OEM coding specifications) |
Product Features
- Fully Customizable Electrical ArchitectureBased on OEM equipment topology and spatial constraints, provides complete customization from wire gauge (AWG 10~28), conductor material (tinned copper/bare copper/copper-clad aluminum) to insulation rating (105°C~200°C). Supports multi-core, shielded, coaxial, and hybrid configurations, meeting international safety certification requirements such as UL / CSA / TUV / VDE, ensuring seamless integration with the host system.
- High-Precision Impedance and Signal IntegrityFor AC power transmission and DC low-ripple applications, through precise twist pitch control and dielectric material selection (FEP / PTFE / XLPE), characteristic impedance deviation is controlled within ±5%, while achieving extremely low DC resistance of ≤0.5mΩ/m. Combined with 360° braided shield and aluminum foil shield solutions, effectively suppresses EMI/RFI, ensuring zero interference for sensitive signals.
- Industrial-Grade Weather Resistance and Mechanical DurabilityUtilizes oil-resistant, acid-alkali resistant, UV-resistant special jackets (PUR / TPE / Silicone Rubber), with abrasion resistance ≥5 million cycles (per DIN EN 50396). The harness assembly passes -40°C ~ +125°C thermal cycling tests and 96-hour salt spray tests, suitable for harsh environments such as outdoor, automotive, and industrial robots. Tensile structure uses aramid fiber filling, increasing breaking strength by 300%.
- Smart Error-Proof and Blind-Mate Connection SolutionsIntegrates keyed polarization design, color coding, and digital identification systems, supporting IP67~IP68 waterproof connectors (M12 / M8 / HDC / Push-Pull Self-Locking). Optional integrated LED continuity indication or NTC thermistor monitoring enables plug-and-play and real-time status feedback, significantly reducing on-site installation error rates.
- Ultra-Flexible Dynamic Bending and Drag Chain PerformanceSpecifically developed for high-flexibility applications, using special stranding structures (e.g., Class 5/6 stranding) and TPE elastomer insulation, with a bending radius as low as 5×OD, and drag chain cycle life exceeding 20 million cycles (based on ISO 14572 standard). Suitable for continuous motion scenarios such as automated production lines, AGVs, servo motors, and robot joints, with no risk of core breakage.
- Integrated Functional Component Pre-AssemblyCan pre-integrate fuse holders, relays, resistors, diodes, LED indicators, or PTC thermistors inside the harness, reducing the number of external components and solder joints. Through automated pre-assembly processes, ensures electrical parameter consistency of functional modules, helping OEM customers simplify BOM and improve assembly efficiency.
- Full-Process Traceable Quality SystemEach harness is equipped with a unique QR code/laser marking, linked to raw material batches, process parameters (tensile force, resistance, withstand voltage), test data (Hi-Pot 3000V/5s, insulation resistance ≥500MΩ), and factory inspection reports. Supports PPAP/IMDS/COC document delivery, meeting stringent supply chain traceability requirements in automotive, medical, military, and other fields.
- Multi-Country Certification and Global CompliancePre-certification covers mainstream standards such as UL 758/1581, CSA C22.2, IEC 60227/60245, EN 50525, VDE 0282. Also complies with RoHS 3.0, REACH, CA Prop 65, and Low Smoke Zero Halogen (LSZH) requirements, assisting OEM customers in quickly entering North American, EU, and Asia-Pacific markets, shortening product certification cycles.
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 wire harnesses, sensor wire harnesses, high-voltage connection wire harnesses, passing TS16949 quality system, resistant to high temperature and vibration. - Industrial Automation and Equipment
Robot wire harnesses, servo motor wire harnesses, drag chain cables, highly flexible and bend-resistant, adapting to complex industrial environments. - Medical Equipment Wire Harnesses
Medical-grade wire harness customization, biocompatible materials, precision terminal crimping, suitable for monitors, ultrasound equipment, etc.
Frequently Asked Questions
What are the technical requirements for interface compatibility when installing AC/DC wire harnesses?
Before installation, confirm that the harness plug specification (e.g., IEC C13/C14) is fully compatible with the device interface, and check that the polarity marking and voltage rating (e.g., 300V/600V) match to avoid faults caused by incorrect connection.
How to evaluate whether the rated current of an AC/DC wire harness meets equipment requirements during use?
Select the harness based on the maximum load current of the equipment. It is generally recommended that the harness rated current be 20% higher than the actual operating current, and verify by referring to the conductor cross-sectional area (e.g., AWG 18 can carry 10A) and temperature rise curve.
What is the maintenance cycle and key inspection points for AC/DC wire harnesses?
It is recommended to inspect the harness insulation for cracks and plug terminals for oxidation every 6 months, and use a multimeter to test continuity resistance (should be less than 0.1Ω) to ensure no risk of open circuit or poor contact.
When selecting an AC/DC wire harness, how to confirm cable length and shield type based on customization needs?
Please provide the exact length (tolerance ±10mm) and the electromagnetic interference level of the working environment. We can provide unshielded (PVC jacket) or shielded (braided layer) solutions, and support terminal crimping or injection molding customization.
Can AC/DC wire harnesses be used long-term outdoors or in humid environments?
Standard wire harnesses are only for indoor dry environments. For outdoor use, please select a jacket with IP67 waterproof rating and UV-resistant material, and ensure the plug sealing gasket is intact to prevent moisture ingress causing short circuits.
What are the possible causes and troubleshooting methods for localized heating of the wire harness?
Heating is often caused by overload, loose terminals, or increased contact resistance. Immediately cut off power, check if the load exceeds the rated value, and tighten the connection points; if heating persists, replace with a thicker wire gauge or a harness with temperature protection.
What specific value does compatibility certification of AC/DC wire harnesses provide to OEM customers?
We provide UL, CSA, or CE certified wire harnesses, ensuring compliance with international safety standards, reducing customer end-product certification risks, while ensuring long-term reliability through rigorous withstand voltage tests (e.g., 1500V/5 seconds).
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.
