SM terminal wire harness custom processing
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SM terminal wire harness custom processing
SM terminal wire harness is an electronic connecting wire harness using SM terminal interfaces, widely applied in internal circuit connections of various electronic devices. This harness features a compact structure and reliable connections, effectively transmitting signals and power, making it an essential basic component in electronic assembly. Product Features: Uses high-quality copper terminals with low contact resistance and excellent conductivity; wire selection uses flexible oxygen-free copper cores, resistant to bending and stretching, extending service life; insulation layer is made of environmentally friendly PVC or silicone material, high-temperature resistant, flame retardant, and free of pungent odors; supports customization of various lengths, wire diameters, and terminal specifications to meet different application needs; terminals and wires are firmly crimped and pass strict pull tests to ensure no breakage during long-term use. Technical Parameters: Rated voltage: ≤300V; Rated current: ≤5A (depending on wire diameter); Applicable wire gauge: 22AWG ~ 28AWG; Operating temperature: -20℃ ~ +105℃ (PVC insulation) / -40℃ ~ +125℃ (silicone insulation); Terminal material: Phosphor bronze tin-plated or gold-plated; Insulation resistance: ≥100MΩ. Application Scenarios: Home appliances: internal connections for washing machines, rice cookers, air conditioners, etc.; Automotive electronics: wire harnesses for car lights, sensors, central control systems; Industrial control: PLC, frequency converters, signal transmission wire harnesses; Communication equipment: internal wiring for routers, switches, base stations.
Technical Specifications
| Terminal Type | SM Terminal |
| Wire Gauge | 22AWG |
| Rated Voltage | 300V |
| Rated Current | 3A |
| Operating Temperature | -25℃ ~ +85℃ |
| Insulation Material | PVC |
Product Features
- Supports customization of wire length and terminal quantity
- Stable connection, vibration resistant
- Suitable for internal connections in home appliances and electronic devices
- High processing precision, low contact resistance
Applicable 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 wire harnesses, high-voltage connection wire harnesses, passing TS16949 quality system, high temperature and vibration resistant. - Industrial Automation and Equipment
Robot wire harnesses, servo motor wire harnesses, drag chain cables, high flexibility and bending resistance, adapting to complex industrial environments. - Medical Device Wire Harnesses
Medical-grade wire harness customization, biocompatible materials, precision terminal crimping, suitable for monitors, ultrasound equipment, etc.
Frequently Asked Questions
What is the difference between national standard and American standard wire harnesses?
The main differences between the national standard (GB/T 5023) and the American standard (UL 758/AWM): ① Nominal cross-section – The national standard uses mm² as the unit (e.g., 0.5/0.75/1.0mm²), while the American standard uses AWG (e.g., 22/20/18AWG);
② Testing methods – The national standard focuses on conductor resistance and insulation resistance, while the American standard focuses on mechanical properties (bending/tension/impact);
③ Certification labels – American standard harnesses must print UL/AWM numbers, while national standard harnesses print CCC certification numbers;
④ Customer base – UL certification is required for export to the US/Canada, while CCC certification is required for domestic sales in China. Yingna Technology's wire harnesses meet both national and American standards, with traceable UL certification numbers.
② Testing methods – The national standard focuses on conductor resistance and insulation resistance, while the American standard focuses on mechanical properties (bending/tension/impact);
③ Certification labels – American standard harnesses must print UL/AWM numbers, while national standard harnesses print CCC certification numbers;
④ Customer base – UL certification is required for export to the US/Canada, while CCC certification is required for domestic sales in China. Yingna Technology's wire harnesses meet both national and American standards, with traceable UL certification numbers.
How to waterproof wire harnesses used outdoors?
The insulation layer of our wire harnesses is inherently water-resistant (silicone rubber/PVC does not absorb water), but for outdoor exposed use, it is recommended to enhance waterproofing with the following solutions: 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 for enhanced mechanical protection;
④ Use potting compound (epoxy resin or polyurethane) at connection points for permanent waterproofing. With these solutions, long-term underwater connections (10 meters depth) can be achieved, suitable for scenarios like LED underwater lights, sewage treatment equipment, and marine wire harnesses.
② Add waterproof heat shrink tubing (with hot melt adhesive) at crimping points;
③ Use PVC or PE protective sleeves over the cable for enhanced mechanical protection;
④ Use potting compound (epoxy resin or polyurethane) at connection points for permanent waterproofing. With these solutions, long-term underwater connections (10 meters depth) can be achieved, suitable for scenarios like LED underwater lights, sewage treatment equipment, and marine wire harnesses.
Will wire harnesses age after long-term use? How to extend service life?
Under normal usage conditions, the service life of our silicone rubber material is 10~15 years, and PVC material is 5~8 years. Factors affecting lifespan: ① Operating temperature – Long-term operation at the rated temperature limit accelerates aging (halving lifespan);
② Bending frequency – Use high-flex wire harnesses for frequent bending applications (bending life ≥10 million cycles);
③ Environmental factors – UV rays, ozone, and chemical solvents accelerate aging of the silicone rubber outer layer. Suggestions to extend lifespan: Maintain a 20% margin below the operating temperature, avoid contact with chemical solvents, install protective sleeves for fixed wiring, and regularly check if the terminal crimping points are overheating.
② Bending frequency – Use high-flex wire harnesses for frequent bending applications (bending life ≥10 million cycles);
③ Environmental factors – UV rays, ozone, and chemical solvents accelerate aging of the silicone rubber outer layer. Suggestions to extend lifespan: Maintain a 20% margin below the operating temperature, avoid contact with chemical solvents, install protective sleeves for fixed wiring, and regularly check if the terminal crimping points are overheating.
What is the minimum order quantity for custom wire harnesses? How are sample fees calculated?
The minimum order quantity (MOQ) for standard wire harness products is 1000 meters/specification; for simple customization (e.g., color, printing), the MOQ can be as low as 500 meters. For first-time cooperation, sampling can be arranged: sample length 1~5 meters, sample fee 200~500 RMB (including UL certification labels). The sample fee will be refunded upon batch order placement after sample approval. Batch order delivery time is typically 7~15 working days (depending on quantity and complexity). Rush orders can be scheduled for priority production (rush fee approximately 15%), with delivery time compressed to 3~5 working days.
What is the flame retardant rating of the wire harness? Does it comply with UL VW-1 standard?
Our wire harnesses achieve a flame retardant rating of UL VW-1 (vertical flame test), which is the minimum flame retardancy requirement of the UL 758 electronic wire standard. Higher flame retardant ratings are available: UL VW-1+ vertical flame, UL FT2 (horizontal flame), UL VW-1+FT2 dual certification. Significance of flame retardant standards: A VW-1 rated harness, in a vertical flame test, after 5 applications of 15-second flames, the flame self-extinguishes within 60 seconds, does not ignite the cotton below, and has no burning drips. For applications with high fire safety requirements (e.g., inside new energy vehicle battery packs, medical equipment), it is recommended to choose wire harnesses with higher flame retardant ratings.
Can this wire harness be used on medical equipment? What standards need to be met?
Our standard wire harnesses are not recommended for direct use inside medical equipment. Medical device wire harnesses must meet the IEC EN60601 standard, requiring: ① Low leakage current – Standard harness leakage current ≤0.5mA, medical grade ≤0.1mA;
② Biocompatibility – Insulation layer and terminal materials must pass ISO 10993 biocompatibility testing;
③ High isolation voltage – Reinforced insulation, isolation voltage ≥4000V;
④ Cleanliness – Produced in a cleanroom, free from ionic contamination. Yingna Technology can customize medical-grade wire harnesses (including EN60601 certification). Technical parameters and certification requirements must be communicated in advance for separate production arrangements.
② Biocompatibility – Insulation layer and terminal materials must pass ISO 10993 biocompatibility testing;
③ High isolation voltage – Reinforced insulation, isolation voltage ≥4000V;
④ Cleanliness – Produced in a cleanroom, free from ionic contamination. Yingna Technology can customize medical-grade wire harnesses (including EN60601 certification). Technical parameters and certification requirements must be communicated in advance for separate production arrangements.
What is the insulation material of this wire harness? Does it meet environmental requirements?
Our insulation material uses silicone rubber or PVC material, selected based on the model and specification. Silicone rubber withstands temperatures from -60℃ to 200℃, and PVC withstands -20℃ to 105℃. The entire series of wires complies with RoHS 10-item testing and REACH SVHC screening, free from harmful substances like lead, mercury, and cadmium, and can provide third-party SGS test reports. Electronic wires exported to North America need to meet UL VW-1/FT2 flame retardant ratings, and those exported to Europe need to meet the CE Low Voltage Directive.
How to judge the quality of a wire harness?
3 methods to quickly identify wire harness quality: ① Visual inspection – The insulation layer surface should be smooth, free from burrs, bubbles, color differences, or eccentricity;
② Bending test – After 100 repeated bends, the insulation layer should have no cracks (silicone rubber) or significant whitening (PVC);
③ Flame test – High-quality harnesses self-extinguish within ≤30 seconds after removing the flame (UL VW-1/FT2 standard), while poor-quality harnesses continue to burn and have drips. Additionally, measure the insulation thickness (whether it meets UL standards) and conductor resistance (≤UL specified maximum). Before bulk purchasing, it is recommended to request samples from the supplier for comprehensive quality confirmation.
② Bending test – After 100 repeated bends, the insulation layer should have no cracks (silicone rubber) or significant whitening (PVC);
③ Flame test – High-quality harnesses self-extinguish within ≤30 seconds after removing the flame (UL VW-1/FT2 standard), while poor-quality harnesses continue to burn and have drips. Additionally, measure the insulation thickness (whether it meets UL standards) and conductor resistance (≤UL specified maximum). Before bulk purchasing, it is recommended to request samples from the supplier for comprehensive quality confirmation.
What is the temperature range of the wire harness? Can it be used long-term in high-temperature environments?
The temperature resistance range of this wiring 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, and inside new energy vehicle battery packs), silicone rubber wiring harnesses must be used. PVC material in such scenarios will accelerate aging and cause insulation cracking. For low-temperature environments (such as outdoor extreme cold regions) and high-low temperature cycling conditions, silicone rubber wiring harnesses are also recommended.
What certifications does this wiring harness have? Can certification reports be provided?
This wiring harness is certified by UL (USA) and CE (EU), and complies with RoHS environmental and REACH regulatory requirements. The UL certification number is traceable, and CE declaration documents are complete. For bulk purchases, the following can be provided simultaneously: UL certification copy, Material Declaration Sheet (MDS), SGS environmental test report, and product flame retardant test report. For customers with special certification requirements (such as VDE, CCC, PSE, KC, etc.), please inform us in advance, and separate certification applications can be arranged.
Can the color of the wiring harness be customized?
Any color can be customized. Usually, providing a Pantone color number or color swatch is sufficient for color matching. Common stock colors: black, white, red, blue, yellow, green (24~48 hours shipping). The MOQ for custom colors depends on the specification (usually 1000 meters minimum), with delivery extended by 3~5 working days. Printing/logo marking service: Model numbers, LOGOs, certification marks, etc., can be printed on the harness surface as required, supporting both thermal transfer and inkjet processes. Please provide a draft of the printed content for confirmation to avoid errors.
What after-sales services are provided after purchasing the wiring harness?
Winna Technology wiring harness products come with a standard 2-year warranty. Non-human damage within the warranty period is repaired or replaced free of charge. Domestic customers enjoy a 48-hour response 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 the new product). Lifetime technical support is provided, including wiring 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.
About Winna Technology
Specializing in the R&D and production of power adapters, AC/DC wiring harness customization, and ultrasonic metal welding equipment, providing one-stop OEM/ODM services.
Products are certified by CE/UL/FCC/CCC/RoHS, with an annual return rate below 0.02%, serving customers in 50+ countries and regions globally.
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