Details
Product OverviewCommunication wire harnesses are integrated components used for signal transmission and power connection, playing a key role in communication equipment. This product adopts precision processing technology to ensure that the conductivity, insulation and anti-interference capability of each harness meet industry standards, and it is suitable for various complex communication environments. AsAC/DC wire harnessan important component, communication wire harnesses play a bridging role in power conversion and signal transmission, ensuring stable system operation.Product FeaturesHigh reliability:High-quality copper conductors and flame-retardant insulation materials are used, wear-resistant and corrosion-resistant. The conductor can be high-purity oxygen-free copper (OFC) with conductivity up to 100% IACS, ensuring no insulation aging or short-circuit risk under long-term full-load conditions.Signal integrity:Precision stranding and shielding structure effectively suppress electromagnetic interference and ensure stable high-speed data transmission. By optimizing the cable stranding pitch and shield grounding method, stable electrical performance is maintained under harsh operating conditions.Customization flexibility:Length, interface, color and terminal type can be customized according to customer drawings or samples. Supports various connector series such as JST, Molex, TE/AMP, Hirose DF, JAE, meeting different current and pitch requirements.Efficient assembly:Modular design facilitates on-site installation and maintenance, reducing wiring costs. Pre-insulated terminal design (O-type/Y-type) is easy to install, saving working hours.Strict quality inspection:100% continuity test, insulation withstand voltage test and visual inspection, zero-defect delivery. Qualified wire harness standards include: terminal crimp height within specification range, tensile test meeting UL standard requirements, no breakdown or flashover in withstand voltage test, insulation resistance ≥100MΩ, etc.Technical ParametersParameterSpecificationWire sizeAWG28~AWG16, multi-core combination supportedInsulation materialPVC, TPE, XLPE optional (temperature rating 80°C/105°C/125°C)Shielding methodBraided shield, aluminum foil shield or unshieldedRated voltage300V/600V ACOperating temperature-40°C~+105°C (silicone wire can reach -60°C~+200°C)Interface typeRJ45, DB9, USB, aviation plug, MOLEX Micro-Fit 3.0, etc.Flame retardant ratingUL VW-1, CSA FT1Environmental standardsRoHS 2.FAQ
What should I look for when choosing a communication wire harness for harsh or complex environments?
Focus on four things: conductor quality, insulation, shielding, and termination. Look for high-purity oxygen-free copper (OFC) with conductivity up to 100% IACS for low resistance and stable power transfer, flame-retardant and corrosion-resistant insulation to prevent aging or short circuits under continuous full load, and precision stranding with an optimized shield grounding method to suppress electromagnetic interference. These factors together determine whether the harness will hold up in demanding communication equipment.
Can communication wire harnesses be customized to specific lengths, connectors, and terminal types?
Yes. Length, interface, color, and terminal type can all be customized from customer drawings or samples. Common connector series including JST, Molex, TE/AMP, Hirose DF, and JAE are supported, so different current ratings and contact pitches can be matched to your board layout and cable routing. If you are designing a new assembly, supplying a drawing or a physical sample is usually the fastest route to an accurate quote.
Ultrasonic welding vs crimping — which termination is better for a wire harness?
It depends on the joint requirements. Crimping is fast and well established, but it creates a mechanical contact rather than a metallurgical bond, so resistance can drift over time and oxidation can develop in the joint. Ultrasonic welding produces a solid-state, oxide-free weld with lower contact resistance and higher, more consistent pull force, which matters in high-current or vibration-heavy applications. Crimping still makes sense for low-cost, low-current signal lines and where rework flexibility is needed. Many harnesses combine both: crimped connectors at the ends and ultrasonically welded splices or terminals at the high-current junctions.
Does ultrasonic welding work for copper-to-aluminum wire harness terminations?
Yes — it is one of the main reasons ultrasonic welding is chosen. Copper and aluminum cannot be reliably joined by fusion welding because of their different melting points and brittle intermetallics, but ultrasonic welding joins them in the solid state below melting temperature, producing a durable, low-resistance copper-aluminum connection. This makes it suitable for mixed-metal harness assemblies, busbars, and battery tab applications where weight reduction or material cost drives aluminum use.
How do I verify the strength and quality of an ultrasonically welded harness joint?
Request pull force (tensile) test data and cross-section analysis from the supplier. Pull force testing confirms the weld meets the specified mechanical strength for the wire gauge, while a cross-section shows weld area, compaction, and absence of voids or cracks. For battery tab and high-current applications, also ask for resistance or voltage-drop measurements, since a joint with good pull force can still have elevated resistance if the weld area is too small. Consistent weld quality depends on properly matched power, amplitude, pressure, and weld time, so the supplier should be able to show process control for each wire and terminal combination.
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.
