GX aviation connector cable harness power cable is a high-performance connection component designed for applications requiring reliable electrical connections. It uses GX series aviation plugs combined with precision cable harness processing technology to achieve efficient transmission of power and signals, widely used in military, industrial equipment, and outdoor electronic systems. Product features: GX aviation plug with IP67 waterproof and dustproof performance, suitable for harsh environments; gold-plated contact terminals with low contact resistance, plug life over 5000 cycles; cable harness uses high-quality PVC or silicone sheath, oil-resistant, corrosion-resistant, and anti-aging; supports customization of cable length, diameter, core count, and plug angle to meet diverse needs; complies with RoHS standards, safe and environmentally friendly. Technical parameters: Rated current: 5A-30A (depending on core count); Rated voltage: 300V/500V; Number of cores: 2-12 cores (standard); Protection level: IP67 (when mated); Operating temperature: -40℃~+85℃; Insulation resistance: ≥1000MΩ. Application scenarios: Internal and external connections of industrial automation equipment; power transmission for outdoor LED displays and landscape lighting; cable harnesses for security surveillance cameras and sensors; marine electronics and rail transit signal systems; stage lighting and audio equipment connections.
Technical specifications
| Terminal type | GX16/20/25 series circular aviation plug |
| Wire gauge | 18-22 AWG |
| Rated voltage | 250V AC/DC |
| Rated current | 5-10A |
| Operating temperature | -40°C ~ +105°C |
| Insulation material | PVC/silicone rubber |
| Waterproof rating | IP67 (optional) |
Product features
- High-reliability connection, suitable for harsh industrial environments
- Supports customization of cable length, terminal plating, and sheath material
- Plug life over 500 cycles, low contact resistance
- Optional shielding layer design, anti-electromagnetic interference
- Complies with RoHS and REACH environmental standards
Application scenarios
- Home appliances and consumer electronics
Customization of power cables, signal cables, and ribbon cables, meeting ROHS/REACH environmental standards, suitable for white goods and small appliances. - Automotive electronics and new energy
Automotive cable harnesses, sensor cable harnesses, high-voltage connection cable harnesses, certified under TS16949 quality system, high temperature and vibration resistant. - Industrial automation and equipment
Robot cable harnesses, servo motor cable harnesses, drag chain cables, high flexibility and bending resistance, adaptable to complex industrial environments. - Medical device cable harnesses
Medical-grade cable harness customization, biocompatible materials, precision terminal crimping, suitable for monitors, ultrasound equipment, etc.
Frequently asked questions
What after-sales services are available after purchasing the cable harness?
Yingna Technology cable harness products have a standard warranty of 2 years. Free repair or replacement for non-human damage within the warranty period. Domestic customers enjoy a 48-hour response and completion of repair within 7 working days; overseas customers can arrange repair via DHL/FedEx. Products beyond the warranty period are eligible for paid repair services (cost approximately 30-50% of new product). Lifetime technical support is provided, including cable harness selection consultation, terminal processing solutions, and quality issue diagnosis. Annual framework agreement customers enjoy value-added services such as priority production scheduling, free samples, and factory inspection support.
What is the conductor material of this cable harness? Bare copper or tinned copper?
This unit uses multi-strand tinned copper wire conductors, balancing conductivity and corrosion resistance. Bare copper conductivity is about 101% IACS, tinned copper about 98% IACS (difference only about 3%). Advantages of tinning: 3-5 times stronger oxidation resistance, better solderability (avoids soldering issues), significantly improved corrosion resistance. For high-reliability scenarios such as new energy vehicles and outdoor equipment, tinned copper wire cable harnesses are recommended.
Will the cable harness age after long-term use? How to extend its service life?
Under normal use conditions, the silicone rubber material of this cable harness has a service life of 10-15 years, and PVC material 5-8 years. Factors affecting lifespan: ① Operating temperature—long-term operation at the rated temperature upper limit accelerates aging (halving lifespan);
② Bending frequency—use high-flex cable harnesses for frequent bending applications (bending life ≥10 million cycles);
③ Environmental factors—UV, ozone, and chemical solvents accelerate aging of the silicone rubber outer layer. Suggestions to extend life: leave a 20% margin in operating temperature, avoid contact with chemical solvents, add protective sleeves for fixed wiring, and regularly check if the terminal crimping area is heating up.
What is the minimum bending radius of the cable harness? Can it be used for wiring in tight spaces?
The minimum bending radius of this cable harness is 5 times the cable diameter, much smaller than the 10 times requirement for ordinary PVC cables. Due to the multi-strand ultra-fine tinned copper wire stranded structure, the cable harness has excellent flexibility and can be flexibly routed in tight spaces such as phones, sensors, car door panels, and LED lights, without easily breaking the core even with frequent bending. For applications requiring a smaller bending radius (e.g., robot drag chains), a high-flex drag chain-specific cable harness can be selected.
Can the cable harness be processed with terminals? What types of terminals are supported?
Yingna Technology provides cable harness terminal processing services, supporting various terminal types: pre-insulated terminals (O-type/U-type/pipe-type), bare terminals (OT/SC/GT), flag terminals, closed terminals, spade terminals, etc. Terminal crimping uses fully automatic crimping machines, with crimping pull force meeting UL 486A standards. Customer-supplied materials (cable + terminals) or specified brand and model terminals are acceptable. Adding heat shrink tubing or insulation sleeves after terminal crimping can further improve insulation performance and mechanical strength.
What is the flame retardant rating of the cable harness? Does it meet the UL VW-1 standard?
The flame retardant rating of this cable harness reaches UL VW-1 (vertical flame test), which is the minimum flame retardant requirement of the UL 758 electronic wire standard. Higher flame retardant ratings are optional: UL VW-1+ vertical flame, UL FT2 (horizontal flame), UL VW-1+FT2 dual certification. Significance of flame retardant standards: Cable harnesses passing VW-1, in a vertical flame test after 5 times of 15-second burning, the flame self-extinguishes within 60 seconds, does not ignite the cotton below, and has no burning drips. For applications with high fire protection requirements (e.g., inside new energy vehicle battery packs, medical equipment), cable harnesses with higher flame retardant ratings are recommended.
How to waterproof the cable harness when used outdoors?
The insulation layer of this cable harness itself is water-resistant (silicone rubber/PVC does not absorb water), but for outdoor exposed use, the following solutions are recommended to enhance waterproofing: ① Use IP67/IP68 grade waterproof connectors;
② Add waterproof heat shrink tubing (with hot melt adhesive) at crimping points;
③ Use PVC or PE protective sleeves over the cable to enhance mechanical protection;
④ Use potting compound (epoxy resin or polyurethane) at connections for permanent waterproofing. With these solutions, long-term underwater connections (10 meters depth) can be achieved, suitable for scenarios such as LED underwater lights, sewage treatment equipment, and marine cable harnesses.
What is the difference between new energy vehicle cable harnesses and ordinary cable harnesses?
New energy vehicle (EV/HEV) cable harnesses must meet higher standards: ① Temperature rating—battery pack internal temperature can reach 85-150℃, silicone rubber cable harnesses must be used (PVC cannot meet this);
② Voltage rating—high-voltage connection cable harnesses withstand 600V-1000V, much higher than ordinary 300V;
③ EMC shielding—high-voltage cable harnesses need a braided shielding layer to prevent electromagnetic interference (EMC, compliant with CISPR 25 standard);
④ Flame retardant requirement—VW-1 + low smoke zero halogen (LSZH);
⑤ Vibration resistance—terminal crimping must not loosen under high-frequency vibration (vehicle operation);
⑥ TS16949 automotive quality management system certification. Ordinary cable harnesses do not meet the above requirements and are prohibited for use in new energy vehicles.
What certifications does this cable harness have? Can certification reports be provided?
This cable harness has passed UL (USA) and CE (EU) certifications, and complies with RoHS environmental and REACH regulations. UL certification numbers are traceable, and CE declaration documents are complete. For bulk purchases, the following can be provided simultaneously: UL certification copy, material declaration (MDS), SGS environmental test report, and product flame retardant test report. For customers with special certification requirements (e.g., VDE, CCC, PSE, KC), please inform in advance, and separate certification applications can be arranged.
What is the temperature range of the wiring harness? Can it be used in high-temperature environments for extended periods?
The temperature range of this wiring harness depends on the insulation material: Silicone rubber insulation -60℃~+200℃ (short-term peak 250℃), PVC insulation -20℃~+105℃. In high-temperature environments (such as automotive engine compartments, industrial furnace surroundings, and inside new energy vehicle battery packs), silicone rubber wiring harnesses must be used. PVC material will accelerate aging and cause insulation cracking in such scenarios. For low-temperature environments (such as outdoor extreme cold regions) and high-low temperature cycling conditions, silicone rubber wiring harnesses are also recommended.
What is the insulation material of this wiring harness? Does it meet environmental requirements?
The insulation material of this unit is silicone rubber or PVC, selected based on the model and specifications. Silicone rubber withstands temperatures from -60℃ to 200℃, while PVC withstands -20℃ to 105℃. The entire series of wires complies with RoHS 10-item testing and REACH SVHC screening, free of lead, mercury, cadmium, and other hazardous substances. Third-party SGS test reports are available. For export to North America, electronic wires must meet UL VW-1/FT2 flame retardant ratings; for export to Europe, they must comply with the CE Low Voltage Directive.
How to judge the quality of a wiring harness?
Three methods to quickly assess wiring harness quality: ① Visual inspection—the insulation surface should be smooth, free of burrs, bubbles, color deviation, and eccentricity;
② Bending test—after 100 repeated bends, the insulation should show no cracks (for silicone rubber) or significant whitening (for PVC);
③ Combustion test—high-quality wiring harnesses self-extinguish within ≤30 seconds after removing the flame (UL VW-1/FT2 standard), while inferior ones continue burning or produce dripping. Additionally, measure insulation thickness (whether it meets UL standards) and conductor resistance (≤UL specified maximum). Before bulk procurement, it is recommended to request samples from the supplier for comprehensive quality confirmation.
