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?
What is the maximum operating voltage and current range of AC/DC wire harness?
How to ensure the service life of the harness in high-temperature environments?
How to maintain the harness to extend its service life?
What technical parameters need to be provided when customizing AC/DC wire harness?
What mainstream device interfaces are compatible with the harness?
How to troubleshoot when the harness has poor contact?
How to ensure quality consistency when purchasing harnesses in bulk?
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 →
