Details
AC/DC wire harnesses are customized connection components designed for power conversion systems, supporting wire gauge specifications from 2.5mm² to 6mm² and certified to UL 758. The core value lies in providing high-reliability electrical connections and flexible customization solutions, suitable for industrial equipment, medical instruments, server power supplies, and other scenarios.
Technical Specifications
| Parameter Name | Technical Specifications / Typical Values |
| Rated Voltage (AC/DC) | 300 V AC / 300 V DC (UL 758) |
| Rated Current (A) | 15 A (based on 18 AWG, ambient temperature 30°C) |
| Conductor Specification (AWG / mm²) | 18 AWG (0.824 mm²) · Tinned copper stranded wire |
| Insulation Material & Temperature Rating | PVC (105°C) or XLPE (125°C) |
| Shielding Type / Anti-Interference | Aluminum foil + tinned copper braid (85% coverage) |
| Connector System (Compatibility) | IEC 60320 C13/C14 · NEMA 5-15R · Molex Mini-Fit Jr. |
| Operating Ambient Temperature | -40°C ~ +105°C (PVC insulation) |
| Bending Life (Cycles) | > 10,000 cycles (dynamic bending test, R=10 mm) |
| Certifications / Safety Standards | UL 758 · CSA C22.2 No.210 · CE (LVD) |
| OEM Customization Scope | Wire gauge/color/marking/connector/shielding/length (0.2m~30m) |
Product Features
- High-Precision Custom Design: Supports full customization based on OEM customer-provided electrical parameters, wire gauge, length, and connector type, ensuring optimal matching of the harness with the terminal device in current carrying capacity, voltage rating, and spatial layout.
- Wide Voltage/Current Compatibility Range: AC/DC wire harnesses can cover a wide range of electrical requirements from low-voltage signals (5V DC) to high-voltage power (600V AC), while supporting current carrying capacity from 0.5A to 30A, meeting diverse industrial application scenarios.
- Enhanced Insulation and Temperature Resistance: Uses UL-certified high-temperature resistant, flame-retardant insulation materials (such as PVC, silicone rubber, or TPE), with temperature ratings up to 105°C to 200°C, effectively addressing thermal stress and electrical safety challenges under high load or harsh environments.
- Multi-Country Safety Certification Compatibility: Harness design complies with international safety standards such as UL, CE, CCC, VDE, allowing flexible selection of certification levels based on the OEM target market, reducing compliance risks for customer product exports.
- Modular Connector System: Provides various standardized and customized connector interfaces such as IEC, NEMA, Molex, JST, supporting quick plug-in/out and anti-misinsertion structures, improving assembly efficiency and system reliability.
- EMC Shielding and Anti-Interference Optimization: For high-frequency AC/DC conversion scenarios, optional braided shield or aluminum foil shield layers effectively suppress electromagnetic radiation and external interference, ensuring signal integrity and system stability.
- Full Traceability Quality System: Each harness undergoes continuity testing, withstand voltage testing, and insulation resistance testing, and is accompanied by a unique serial number and factory report, achieving full lifecycle quality traceability from raw materials to finished products.
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 harnesses, high-voltage connection harnesses, passing 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, adapting to complex industrial environments. - Medical Device Harnesses
Medical-grade harness customization, biocompatible materials, precision terminal crimping, suitable for monitors, ultrasound equipment, etc.
Frequently Asked Questions
What key points should be noted during AC/DC wire harness installation?
How to determine if the harness compatibility meets OEM equipment requirements?
What are common causes of poor contact during harness use?
How should the maintenance cycle for AC/DC wire harnesses be set?
When purchasing OEM harnesses, what technical parameters reflect customization capabilities?
How do the rated current and voltage of the harness affect equipment lifespan?
How to verify if the harness meets safety certification standards? Frequently Asked QuestionsCheck whether the harness has certification marks such as UL, CE, or CCC, and verify the withstand voltage, insulation resistance, and flame retardant performance data in the test report to ensure compliance with mandatory safety requirements of the target market. What key points should be noted during AC/DC wire harness installation?Related Products During installation, ensure the harness fully matches the device interface to avoid reverse polarity; also check that the cable insulation is undamaged, and select appropriate specifications based on rated current and voltage parameters to ensure electrical safety.You may also be interested in our other models: How to determine if the harness compatibility meets OEM equipment requirements?Pre-Insulated Terminal Wires O-Type Y-Type Power Ground Wires Check the harness interface type, rated voltage (e.g., AC/DC range), current capacity, and operating temperature range, and refer to the electrical parameters in the equipment technical manual to ensure the custom harness meets the original design standards.Yaskawa Servo Brake Power Cable High-Flexibility Servo Harness What are common causes of poor contact during harness use?Red and White Ribbon Cable Oil-Resistant Heat-Resistant Flame-Retardant Eco-Friendly Ribbon Cable Common causes include oxidation or loosening of connectors, internal breakage due to excessively small cable bending radius, and terminal thermal aging from long-term overload. It is recommended to regularly inspect connection points and avoid mechanical stress concentration.Blue and White Ribbon Cable High-Precision Oxygen-Free Copper UL2468 How should the maintenance cycle for AC/DC wire harnesses be set?About Winna Technology It is generally recommended to perform a visual inspection every 6 months, focusing on insulation cracks, plug corrosion, and cable wear; in high-temperature or humid environments, shorten the cycle to every 3 months to ensure stable electrical performance.Specializing in power adapters, AC/DC wire harness customization, and ultrasonic metal welding equipment R&D and production, providing OEM/ODM one-stop services. When purchasing OEM harnesses, what technical parameters reflect customization capabilities?Products certified with CE/UL/FCC/CCC/RoHS, annual return rate below 0.02%, serving customers in over 50 countries and regions globally. Customization capabilities include harness length, conductor cross-sectional area, connector model (e.g., Molex or JST), shielding requirements, and flame retardant rating (e.g., UL VW-1), which can be flexibly adjusted based on equipment space and current needs.+86 13410650093 How do the rated current and voltage of the harness affect equipment lifespan?liuyan@winna-group.com If the harness rating is lower than the actual equipment demand, it can cause overheating and accelerated insulation aging, shortening lifespan; selecting a harness with higher margin (e.g., rating 20% above the load) can improve reliability, especially for high-power AC/DC applications.WhatsApp How to verify if the harness meets safety certification standards? Check whether the harness has certification marks such as UL, CE, or CCC, and verify the withstand voltage, insulation resistance, and flame retardant performance data in the test report to ensure compliance with mandatory safety requirements of the target market. Related Products You may also be interested in our other models: Pre-Insulated Terminal Wires O-Type Y-Type Power Ground Wires Yaskawa Servo Brake Power Cable High-Flexibility Servo Harness Red and White Ribbon Cable Oil-Resistant Heat-Resistant Flame-Retardant Eco-Friendly Ribbon Cable Blue and White Ribbon Cable High-Precision Oxygen-Free Copper UL2468 About Winna Technology Specializing in power adapters, AC/DC wire harness customization, and ultrasonic metal welding equipment R&D and production, providing OEM/ODM one-stop services. Products certified with CE/UL/FCC/CCC/RoHS, annual return rate below 0.02%, serving customers in over 50 countries and regions globally. +86 13410650093 liuyan@winna-group.com WhatsApp Contact Us →Contact Us →
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 →
