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?
How to select the appropriate AC/DC wire harness specification based on equipment needs?
Common faults and troubleshooting methods for AC/DC wire harnesses in use?
What is the maintenance cycle and care method for the harness?
What technical parameters need to be provided when customizing AC/DC wire harnesses?
How to verify harness compatibility, especially for different brand devices?
What environmental standards and quality certifications do AC/DC wire harnesses have?
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 →
