Details
AC/DC wire harness is a customized component integrating power cables and connectors, UL certified, supporting 10A-30A current specifications, providing stable power transmission for industrial equipment and consumer electronics. Core value lies in customizing wire length, terminals, and protection level on demand, ensuring system compatibility and safety reliability.
Technical Specifications
| Parameter Name | Technical Specifications / Performance Indicators |
| Rated Voltage (AC/DC) | AC 250V600V | DC 48V1000V Custom withstand voltage up to 1500V DC UL certified |
| Rated Current (Continuous) | Standard 10A / 16A / 32A / 63A (per wire gauge) Maximum current capacity 120A (with 10AWG2AWG custom) Supports redundant design, temperature rise ≤30°C (rated load) |
| Insulation Resistance & Dielectric Strength | Insulation resistance ≥ 1000 MΩ (500V DC) Dielectric strength: AC 3000V / 1min no flashover or breakdown (can meet customer 4000V reinforced insulation requirements) |
| Conductor Specification & Material | Bare copper stranded wire (bare/tinned/silver-plated) Wire gauge range: 30AWG ~ 2AWG Conductor structure: compliant with IEC 60228 Class 5/6 flexible stranding Optional: copper foil shield / aluminum foil + braid shield |
| Insulation Material / Jacket | PVC (105°C) · Silicone rubber (200°C) · XLPE (125°C) · TPE Flame retardant grade VW-1 / FT1 / FT2 / UL 94 V-0 Halogen-free low smoke type (LSZH) optional |
| Operating Temperature Range | Standard: -20°C +105°C Extended: -55°C +200°C (silicone/Teflon) Storage temperature: -40°C +85°C |
| Connector Interface / Termination | IEC 60320 (C13/C19/C5/C7 etc.) · National standard three-pin · Figure-8 tail · Aviation plug Custom: Molex / JST / TE / Terminal block / Pre-tinned wire ends Protection rating: IP54 ~ IP67 (per connector selection) |
| Shielding & EMC Compatibility | Optional overall braid shield (85% coverage) + aluminum foil Supports grounding spring / ferrite core (EMI suppression) Compliant with EN 55032 / FCC Part 15 Class B |
| Mechanical Life & Reliability | Mating life ≥ 5000 cycles (connector) Bend test ≥ 20000 cycles (harness assembly) Salt spray test 48~96h (per customer grade) |
| Customization Capability & Quality Assurance | ✓ Length accuracy ±2mm · Heat shrink tube/label/Teflon sleeve ✓ 100% electrical test (continuity/insulation/withstand voltage) ✓ Traceable QR code · Compliant with RoHS / REACH / UL / CE |
Product Features
- High-precision Customized Wire Gauge and Length: Supports multiple conductor cross-section specifications from 0.5mm² to 6.0mm², with length tolerance controlled within ±2mm, meeting OEM equipment's stringent requirements for spatial layout and electrical performance.
- Wide Voltage and Current Compatibility: Optimized insulation and conductor structure stably carries AC 100-277V and DC 12-48V voltage range, rated current covers 5A to 30A, suitable for various industrial and consumer electronic terminals.
- Full Range of International Safety Certifications: Products certified by UL, CSA, VDE, CCC, and CE, insulation materials comply with RoHS and REACH standards, ensuring global market compliance and long-term reliability.
- Modular Interface and Terminal Solutions: Provides IEC 60320, NEMA, JIS standard interfaces and customized crimp terminals (including tinned/gold-plated options), compatible with mainstream brand power modules, reducing system integration costs.
- Multi-layer Protection Structure Design: Built-in flame-retardant PVC or TPE jacket, combined with anti-bend strain relief tail and sealing ring, withstands -40°C to +105°C extreme temperatures and oil, vibration environments, extending equipment trouble-free operation cycle.
- Intelligent Error-proofing and Traceability: Optional QR code or RFID tag for full traceability from raw material batch to finished product testing; harness polarity identification uses two-color coding and laser engraving to prevent installation errors.
- Ultra-low Impedance and Electromagnetic Shielding Layer: Uses multi-strand tinned copper conductor and aluminum foil + braided mesh composite shielding structure, reducing wire resistance to 30% below industry standard lower limit, effectively suppressing EMI radiation, ensuring signal integrity.
- Fast Sample Delivery and Batch Consistency: Provides engineering samples within 72 hours, mass production stage through fully automatic terminal crimping and 100% electrical testing (withstand voltage, insulation resistance, continuity), ensuring batch-to-batch performance deviation <1%.
Application Scenarios
- Home Appliances and Consumer Electronics
Power cords, signal wires, ribbon cable customization, meeting ROHS/REACH environmental standards, suitable for white goods and small appliances. - Automotive Electronics and New Energy
Automotive wire harness, sensor harness, high-voltage connection harness, through TS16949 quality system, high temperature and vibration resistance. - Industrial Automation and Equipment
Robot harness, servo motor harness, drag chain cable, high flexibility and bending resistance, adapting to complex industrial environments. - Medical Equipment Harness
Medical-grade harness customization, biocompatible materials, precision terminal crimping, suitable for monitors, ultrasound equipment, etc.
Frequently Asked Questions
How to properly install AC/DC wire harness to avoid electrical faults?
During installation, ensure the harness connector fully matches the equipment interface, tighten torque per technical specifications, avoid excessive bending or stretching of the cable to prevent poor contact or insulation damage.
What is the maximum operating voltage and current range of AC/DC wire harness?
Based on customization needs, standard harness supports 250V AC/DC, current range 1-15A; high-power models up to 600V/30A, specific parameters refer to product specification sheet.
How to ensure the service life of the harness in high-temperature environments?
Uses high-temperature resistant PVC or silicone insulation material, operating temperature range -40°C to +105°C, and passes UL/CE certification, ensuring long-term stable operation.
How to maintain the harness to extend its service life?
Regularly inspect the harness appearance for wear, cracks, or oxidation, keep connectors clean and dry, avoid oil or chemical corrosion, store away from humid and high-temperature areas.
What technical parameters need to be provided when customizing AC/DC wire harness?
Need to provide cable length, conductor cross-section, connector type (e.g., IEC, Molex), rated voltage and current, insulation material and color requirements, we can quickly produce samples per OEM standards.
What mainstream device interfaces are compatible with the harness?
Compatible with IEC 60320, NEMA, DC barrel plug, Anderson and other standard interfaces, can adapt to power adapters, industrial equipment, and medical instruments, providing multi-specification conversion solutions.
How to troubleshoot when the harness has poor contact?
Check connector terminals for oxidation or deformation, use a multimeter to test continuity, confirm no broken core in the cable, replace terminals or re-crimp if necessary to restore conductivity.
How to ensure quality consistency when purchasing harnesses in bulk?
Our company implements ISO 9001 system, each batch undergoes withstand voltage, insulation resistance, and pull force tests, provides full inspection reports, and supports custom anti-counterfeiting labels and individual packaging.
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.
