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?
How to evaluate whether the rated current of an AC/DC wire harness meets equipment requirements during use?
What is the maintenance cycle and key inspection points for AC/DC wire harnesses?
When selecting an AC/DC wire harness, how to confirm cable length and shield type based on customization needs?
Can AC/DC wire harnesses be used long-term outdoors or in humid environments?
What are the possible causes and troubleshooting methods for localized heating of the wire harness?
What specific value does compatibility certification of AC/DC wire harnesses provide to OEM customers?
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 →
