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?
How to determine if an AC/DC wire harness is suitable for my equipment?
How to maintain AC/DC wire harnesses during long-term use?
What are the technical limitations of harness customization capabilities?
What are the common failure causes of AC/DC wire harnesses?
How to select an AC/DC wire harness suitable for high-power equipment?
What is the compatibility testing process for 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 →
