Product Overview
This power cable harness is specifically designed for communication equipment, used for power transmission and signal connection. Manufactured with high-standard processes, it ensures stable operation in various environments. According to industry research, approximately 30% of communication equipment failures stem from power connection issues, and high-quality cable harnesses can significantly reduce such risks, enhancing overall system reliability.
Product Features
- Uses high-purity copper conductors for excellent electrical conductivity, effectively reducing losses
- High-temperature resistant and flame-retardant insulation layer, suitable for harsh working environments
- Precision crimped terminals with low contact resistance, ensuring stable and reliable connections
- Customizable length, color, and connector types based on customer requirements
- Strict quality inspection ensures each cable harness meets factory standards
Industry experts point out that in communication power systems, the insulation and conductivity of cable harnesses directly determine equipment lifespan. This product uses oxygen-free copper and flame-retardant materials, optimized for this specific need. According to market data, the demand for customized cable harnesses in data center and base station applications grows over 15% annually, highlighting the importance of flexible customization.
Technical Parameters
- Rated Voltage: 300V/500V
- Operating Temperature Range: -40℃~+105℃
- Insulation Resistance: ≥100MΩ
- Withstanding Voltage Test: 2000VAC/1min
- Conductor Material: Oxygen-free copper
- Insulation Material: PVC or XLPE (optional)
Application Scenarios
Widely used in communication base stations, switches, routers, data center power distribution, UPS power supplies, industrial control equipment, and power connections for various electronic devices.
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Technical Specifications
| Terminal Type | JST/XH/PH/Molex, etc. |
| Wire Gauge | 16-28 AWG |
| Rated Voltage | 300V |
| Rated Current | 3-15A |
| Operating Temperature | -40°C to +105°C |
| Insulation Material | PVC/XLPE |
| Waterproof Rating | IP67 (optional) |
Product Features
- High-conductivity terminals ensure stable connections
- High-temperature resistant and flame-retardant insulation material, safe and reliable
- Supports custom cable length, terminal, and connector types
- Suitable for communication power supplies and industrial equipment
- Flexible design, resistant to bending, suitable for installation in tight spaces
Application Scenarios
- Home Appliances and Consumer Electronics
Custom 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 wiring harnesses, sensor harnesses, high-voltage connection harnesses, certified under 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, suitable for 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 is the temperature range of the cable harness? Can it be used long-term in high-temperature environments?
The temperature range of this cable harness varies by 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, inside new energy battery packs), silicone rubber material harnesses must be used; PVC material will accelerate aging and cause insulation cracking in such scenarios. For low-temperature environments (e.g., outdoor polar regions) or high-low temperature cycling applications, silicone rubber harnesses are also recommended.
How to judge the quality of a cable harness?
3 methods to quickly identify wire harness quality: ① Visual inspection—smooth insulation surface without burrs, bubbles, color deviation, or eccentricity;
② Bend test—no cracks in insulation (silicone rubber) or significant whitening (PVC) after 100 repeated bends;
③ Flame test—high-quality harness self-extinguishes within ≤30 seconds after flame removal (UL VW-1/FT2 standard), while low-quality harness continues burning with dripping. Additionally, measure insulation thickness (compliance with UL standards) and conductor resistance (≤UL specified maximum). It is recommended to request samples from suppliers for comprehensive quality verification before bulk procurement.
What is the minimum order quantity for custom wire harnesses? How are sampling fees calculated?
The standard minimum order quantity (MOQ) for regular wire harness products is 1000 meters per specification; for simple customization (e.g., color, printing), MOQ can be as low as 500 meters. First-time cooperation can arrange sampling: sample length 1~5 meters, sampling fee 200~500 RMB (including UL certification label). The sampling fee will be refunded upon bulk order placement after sample approval. Bulk order lead time is typically 7~15 working days (depending on quantity and complexity). Rush orders can be accommodated with expedited production (rush fee approximately 15%), reducing lead time to 3~5 working days.
What is the minimum bending radius of the wire harness? Can it be used for wiring in tight spaces?
The minimum bending radius of this wire harness is 5 times the cable diameter, significantly lower than the 10 times requirement for ordinary PVC cables. Due to the multi-strand ultra-fine tinned copper wire stranding structure, the harness offers excellent flexibility, enabling easy wiring in tight spaces such as mobile phones, sensors, car door panels, and LED fixtures, with reduced risk of core breakage even under frequent bending. For applications requiring an even smaller bending radius (e.g., robot drag chains), high-flex drag chain-specific harnesses are available.
Will the wire harness age after long-term use? How can its service life be extended?
Under normal usage conditions, this wire harness has a service life of 10~15 years for silicone rubber material and 5~8 years for PVC material. Factors affecting lifespan: ① Operating temperature—prolonged operation at the rated temperature upper limit accelerates aging (halving lifespan);
② Bending frequency—use high-flex 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. Recommendations to extend lifespan: maintain a 20% margin below operating temperature, avoid contact with chemical solvents, install protective sleeves for fixed wiring, and regularly check terminal crimping points for overheating.
Can the color of the wire harness be customized?
Yes, any color can be customized. Typically, providing a Pantone color number or color swatch is sufficient for color matching. Common stock colors: black, white, red, blue, yellow, green (24~48 hour delivery). Custom color MOQ depends on the specification (usually starting from 1000 meters), with lead time extended by 3~5 working days. Printing/labeling service: model numbers, logos, certification marks, etc., can be printed on the harness surface as required, supporting both thermal transfer and inkjet printing processes. Please provide a draft of the printing content for confirmation to avoid errors.
What is the conductor material of this wire harness? Bare copper or tinned copper?
This product uses a multi-strand tinned copper wire conductor, balancing conductivity and corrosion resistance. Bare copper has a conductivity of approximately 101% IACS, while tinned copper is about 98% IACS (difference of only ~3%). Advantages of tinning: 3~5 times stronger oxidation resistance, better solderability (avoiding soldering issues), and significantly improved corrosion resistance. For high-reliability applications such as new energy vehicles and outdoor equipment, tinned copper wire harnesses are recommended as the priority choice.
What are the differences between new energy vehicle wire harnesses and ordinary wire harnesses?
New energy vehicle (EV/HEV) wire harnesses must meet higher standards: ① Temperature rating—internal battery pack temperatures can reach 85~150°C, requiring silicone rubber harnesses (PVC is insufficient);
② Voltage rating—high-voltage connection harnesses withstand 600V~1000V, far exceeding the ordinary 300V;
③ EMC shielding—high-voltage harnesses require braided shielding to prevent electromagnetic interference (EMC, compliant with CISPR 25 standard);
④ Flame retardancy—VW-1 + Low Smoke Zero Halogen (LSZH);
⑤ Vibration resistance—terminal crimping must not loosen under high-frequency vibration (automotive operation);
⑥ TS16949 automotive quality management system certification. Ordinary harnesses do not meet these requirements and are prohibited for use in new energy vehicles.
What after-sales services are available after purchasing the wire harness?
Winna Technology wire harness products come with a standard 2-year warranty. Non-human-induced damage within the warranty period is eligible for free repair or replacement. Domestic customers enjoy a 48-hour response time and repair completion 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 price). Lifetime technical support is provided, including 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 certifications does this wire harness have? Can certification reports be provided?
This product's wire harness has UL (USA) and CE (EU) certifications, complying with RoHS environmental and REACH regulations. The UL certification number is traceable, and CE declaration documents are complete. Upon bulk purchase, the following can be provided simultaneously: UL certification copy, Material Data Sheet (MDS), SGS environmental test report, and product flame retardancy test report. For customers with special certification requirements (e.g., VDE, CCC, PSE, KC), please inform in advance for separate certification application arrangements.
Can terminals be processed on the wire harness? What types of terminals are supported?
Winna Technology offers wire harness terminal processing services, supporting various terminal types: pre-insulated terminals (O-type/U-type/ferrule), bare terminals (OT/SC/GT), flag terminals, closed-end terminals, and spade terminals. Terminal crimping uses fully automatic crimping machines, with crimp pull force meeting UL 486A standard. Customer-supplied materials (wire + terminals) or specified brand and model terminals are both acceptable. Applying heat shrink tubing or insulation sleeves after terminal crimping can further enhance insulation performance and mechanical strength.
What is the insulation material of this wire harness? Does it meet environmental requirements?
The insulation material of this product is silicone rubber or PVC, selected based on the specific model and specification. Silicone rubber withstands temperatures from -60°C to 200°C, while PVC withstands -20°C to 105°C. The entire series of wires complies with RoHS 10-item testing and REACH SVHC screening, free of harmful substances such as lead, mercury, and cadmium, with third-party SGS test reports available. Electronic wires exported to North America must meet UL VW-1/FT2 flame retardancy ratings, while exports to Europe must comply with the CE Low Voltage Directive.
