Details
AC/DC wire harness is a customized power transmission component, supporting a voltage range of 100-600V and current specifications of 10-30A, with UL certification. Its core value lies in providing high-reliability electrical connection solutions for OEM customers, suitable for demanding applications such as industrial power supplies, medical equipment, and new energy systems.
Technical Specifications
| Parameter Name | Parameter Value / Specification |
| Rated Voltage (AC/DC) | AC 250V / DC 60V (Customizable to 300V / 100V) |
| Rated Current (Continuous) | 10A ~ 30A (Depends on wire gauge and terminal specification, customizable to 50A) |
| Conductor Specification | 18 AWG ~ 10 AWG Stranded Tinned Copper Wire (Customizable to 8 AWG / 6 AWG) |
| Insulation Material / Temperature Rating | PVC (80°C) / Halogen-Free Flame Retardant XLPE (105°C) / Silicone Rubber (200°C) Optional |
| Connector Type (AC End) | IEC 60320 C13/C14, C19/C20, NEMA 5-15P, Custom Terminal Block |
| Connector Type (DC End) | Anderson SB50/SB120, Ring Terminal, Quick-Connect Terminal, Custom Rectangular Connector |
| Shielding and Protection | Optional Aluminum Foil Shield + Tinned Copper Braid (Coverage ≥85%), EMI Resistant |
| Operating Temperature Range | -40°C ~ +105°C (Standard PVC) / -55°C ~ +200°C (Silicone Rubber) |
| Dielectric Strength Test (Insulation Withstand) | AC 1500V / 1min No Breakdown (Customizable to 3000V High-Voltage Type) |
| Custom Length / Packaging | 0.3m ~ 15m (Cut to Order), Available in Reels, Tie-Wrapped Bundles, or Individual PE Bag Packaging |
Product Features
- High-Precision Custom Design: Supports full custom production based on OEM customer-provided electrical parameters, wire gauge specifications, and connector models, ensuring harness length, terminal layout, and insulation material precisely match equipment requirements, eliminating compatibility risks.
- Ultra-Wide Voltage/Current Carrying Capacity: Uses high-purity copper conductors and reinforced insulation processes to stably carry AC 100-600V and DC 5-48V range, with current density up to 30A/mm², meeting stringent industrial power transmission requirements.
- Multi-Country Certification Compatibility: Harness components pass international safety certifications such as UL, CE, CCC, and VDE, and are pre-equipped with IEC 60320 standard interfaces, seamlessly adapting to power systems in different regions, reducing export compliance costs.
- Reinforced EMI Shielding Structure: Built-in tinned copper braid and aluminum foil double-layer shield effectively suppresses electromagnetic interference signals, ensuring signal integrity in high-frequency AC/DC conversion scenarios, suitable for medical and precision instrument fields.
- Extreme Environment Tolerance: Housing uses flame-retardant V-0 rated PVC/TPE material, with a temperature range of -40°C to +105°C, and passes IP67 dust and water ingress tests, suitable for outdoor charging stations and industrial automation equipment.
- Modular Quick Connection Solution: Supports optional push-pull self-locking connectors and quick-connect terminals, enabling tool-free assembly and hot-swap operation, significantly improving OEM production line assembly efficiency and post-maintenance convenience.
- Full Chain Traceability: Each harness is equipped with a unique laser code, linked to production batch, raw material inspection reports, and factory test data, supporting customer real-time quality history tracking via ERP system, ensuring transparent quality control.
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 Equipment Harnesses
Medical-grade custom harnesses, biocompatible materials, precision terminal crimping, suitable for monitors, ultrasound equipment, etc.
Frequently Asked Questions
What are the key installation precautions for AC/DC wire harnesses?
During installation, ensure connectors are tight and polarity is correct, avoiding stress on the harness or exposure to humid environments. It is recommended to use original factory mounting hardware to prevent poor contact due to vibration.
How to select the appropriate AC/DC wire harness specification based on equipment needs?
Confirm the rated voltage, current, and operating temperature range. For example, high-power equipment should use wire gauge AWG 14 or larger, and match with insulation material rated for 150°C to ensure safety margin.
Common faults and troubleshooting methods for AC/DC wire harnesses in use?
Common faults include cable damage or terminal oxidation, leading to voltage drop or intermittent power failure. It is recommended to regularly check insulation integrity and use a multimeter to test if conduction resistance is below 0.1Ω.
What is the maintenance cycle and care method for the harness?
Clean connector contacts quarterly using a non-corrosive cleaner; avoid long-term bending or heavy pressure on the harness. If wire sheath hardening or cracks are found, replace immediately to prevent short circuit risk.
What technical parameters need to be provided when customizing AC/DC wire harnesses?
Provide rated voltage/current, cable length, connector type (e.g., IEC 60320), shielding requirements, and environmental rating (e.g., IP67). Our company supports full parameter customization to meet OEM needs.
How to verify harness compatibility, especially for different brand devices?
Verification requires checking connector pin definitions, electrical characteristics, and mechanical dimensions. Our company offers sample testing services, ensuring seamless compatibility with target equipment through load and insulation tests (e.g., 500V DC).
What environmental standards and quality certifications do AC/DC wire harnesses have?
Products pass UL 758, RoHS, and REACH certifications, cables use halogen-free flame retardant materials. All batches undergo 100% dielectric strength and insulation tests, meeting industrial-grade reliability requirements.
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.
