Details
AC/DC wire harnesses are customized power transmission components, using UL-certified materials, supporting 100V-240V wide voltage input, designed for industrial equipment and power systems, with core value in providing high-reliability connections and precise electrical performance.
Technical Specifications
| Parameter Name | Technical Specifications |
| Rated Voltage | AC 100-300V / DC 12-48V (customizable range) |
| Rated Current | 1A - 15A (customized based on wire diameter and length) |
| Wire Specifications | UL1007 / UL1015 / UL2464, AWG 18~22 (other standards supported) |
| Connector Type | IEC 60320 C13/C14/C15/C19/C20, DC 5521/5525, or customized per customer drawings |
| Dielectric Withstand Voltage | AC 1500V / 1min, no breakdown or flashover |
| Insulation Resistance | ≥100 MΩ (DC 500V) |
| Operating Temperature Range | -20°C ~ +85°C (expandable to -40°C ~ +105°C) |
| Flame Retardant Rating | VW-1 / FT1 / UL94 V-0 (as per customer requirements) |
| Custom Length | 0.15m ~ 10m (±10mm tolerance), special lengths supported |
| Certification Standards | UL / CE / RoHS / REACH (CCC or VDE can be added) |
Product Features
- High-Precision Custom Design: Supports full custom production based on OEM customer-provided electrical parameters, physical dimensions, and connector types, ensuring zero-tolerance matching with terminal equipment interfaces and reducing system integration risks.
- Wide Voltage/Current Compatibility: Through UL/CE certified conductor cross-sections and insulation material selection, it stably carries AC 100-277V and DC 5-48V voltage ranges, while supporting 0.5A to 30A current output, suitable for various industrial and consumer electronics scenarios.
- Multi-Layer Electromagnetic Shielding Structure: Uses aluminum foil + braided copper mesh composite shielding layer design, effectively suppressing EMI/RFI interference, meeting stringent signal integrity requirements for medical equipment, precision instruments, and other scenarios.
- Weather-Resistant Enhanced Insulation Process: The harness outer jacket uses flame-retardant PVC or TPE material, passing -40°C to +105°C thermal cycling tests and IP67 waterproof rating verification, suitable for long-term operation in outdoor, automotive, and high-humidity environments.
- Intelligent Error-Proof Connection Solution: Integrates polarity reverse connection prevention, locking buckles, and color-coding systems, physically eliminating assembly errors such as misinsertion and loosening, improving production line assembly efficiency and terminal reliability.
- Modular Branch Output Architecture: Supports Y-type, T-type, and multi-way parallel branch structures, achieving sealing and stress relief at branch nodes through injection molding integrated forming process, meeting topology requirements of complex power distribution systems.
- Full-Process Traceability Management: Each batch of harnesses is equipped with a laser-engraved unique serial number, traceable to raw material batches, welding parameters, and withstand voltage test data, providing OEM customers with a complete quality closed loop.
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 resistant, 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 key points should be noted during AC/DC wire harness installation?
During installation, ensure the harness matches the equipment interface to avoid overload or short circuit. It is recommended to use professional tools to secure connectors and check insulation integrity to ensure electrical safety.
How to determine if an AC/DC wire harness is suitable for my equipment?
Check the harness's rated voltage, current parameters, and connector specifications to ensure compatibility with the equipment. It is recommended to provide the equipment technical manual; we can customize the harness to meet specific needs.
How to maintain AC/DC wire harnesses during long-term use?
Regularly inspect the harness appearance for wear or aging, keep it dry and clean. Avoid excessive bending or contact with corrosive substances; it is recommended to perform insulation resistance tests every 6 months.
What are the technical limitations of harness customization capabilities?
Customization supports various wire diameters, lengths, connector types, and protection levels; temperature-resistant and flame-retardant materials should be selected based on the application environment. We provide detailed technical parameter tables for reference.
What are the common failure causes of AC/DC wire harnesses?
Common failures include loose connectors, damaged insulation, or broken wire cores, often due to mechanical stress or excessive environmental humidity. Using high-quality sheaths and reinforced connectors can significantly improve reliability.
How to select an AC/DC wire harness suitable for high-power equipment?
Choose a harness with a rated current greater than the equipment's maximum load, and confirm the wire diameter and connector withstand voltage rating. We offer high-power models supporting overcurrent protection design.
What is the compatibility testing process for harnesses?
We perform electrical performance, mechanical strength, and environmental adaptability tests, including voltage dips, plugging life, and temperature rise tests, ensuring seamless connection with standard interfaces.
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.
