High-Voltage Wiring Harness with Ring Terminals

Main Features:

This series of high‑voltage ring‑terminal harnesses is a power‑bridging and equipment‑connection solution specifically designed for high‑current applications. It features high‑purity copper conductors and tinned ring terminals, paired with a high‑temperature‑resistant insulation layer and crimping‑based protective processes, ensuring stable high‑current transmission and highly reliable electrical connections. The harness can be customized to meet specific equipment requirements, with options for conductor gauge, length, and terminal specifications. It offers strong current‑carrying capacity, low contact resistance, and maintains stable performance over long periods without overheating or oxidation. Widely used in battery packs, inverters, industrial equipment, power modules, and other applications, it provides safe and dependable connectivity for high‑current circuits.

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Category:

Wire Harness Modules

Keyword: High-Voltage Wiring Harness with Ring Terminals

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Key Features

High-current, high-current-carrying design : Utilizes high-purity, multi-strand copper conductor wire; wire diameter can be customized as needed, offering strong current-carrying capacity, low contact resistance, minimal heating under high-current operation, and reduced voltage drop.
Tin-plated ring terminal connection : Features tin-plated copper lug terminals that resist oxidation and corrosion, ensure secure crimping, are compatible with bolt-type connections, provide stable contact, and are unlikely to loosen.
High-Temperature Insulation and Protection It employs high-temperature-resistant silicone rubber and cross-linked polyethylene insulation, with a temperature rating of up to 125°C–200°C. It resists aging and cracking under prolonged use, making it well-suited for high-temperature operating conditions.
Crimping and insulation protection are well‑established. The terminals and wires are joined using a professional crimping process, ensuring a secure connection. The crimped joints are protected by insulating sleeves to prevent short circuits and electrical leakage, thereby enhancing electrical safety.
A wide range of customized specifications : Supports customized specifications for wire diameter, length, terminal hole size, and insulation material, ensuring compatibility with the current requirements and installation space of various devices.
High Reliability and Security : Through rigorous current‑load, voltage‑withstand, and vibration testing, it remains resistant to contact failure and overheating even under prolonged use, ensuring the safe operation of equipment.
Environmental Compliance Support : The wire, terminals, and insulating materials all comply with RoHS and REACH environmental standards, employ lead-free manufacturing processes, and meet global market compliance requirements.

Typical application scenarios

Power and Energy Storage Sector : Battery pack series/parallel bridging, inverter power supply connection, and high-current wiring within energy storage equipment.
Industrial Equipment Sector : Power connection and bridging for industrial power modules, high-power equipment, and automation devices.
Automotive and Transportation Sector : Power connections for vehicle-mounted equipment and construction machinery, as well as battery jumper harnesses.
Other scenarios : Various types of equipment and devices requiring high current and highly reliable bolted connections.

Technical Specifications

Wire specifications: High-purity multi-strand copper conductor, with a cross-sectional area of 1.5–25 mm² (customizable to meet current requirements).
Insulation material: High-temperature-resistant silicone rubber / XLPE insulation layer, with a temperature rating of 125°C to 200°C (optional).
Terminal type: Tin-plated copper ring terminals (copper lugs); hole diameter can be customized to match bolt specifications.
Crimping process: cold crimping / hydraulic crimping; terminals are securely connected to conductors, with contact resistance ≤ 0.5 mΩ.
Rated current: Matched to wire gauge; typically 10 A to 100 A+ (higher current ratings available upon request).
Rated voltage: AC/DC 600 V / 1000 V (higher ratings available upon request)
Insulation resistance: ≥1000 MΩ
Withstand Voltage Performance: AC 2000 V/1 min, no breakdown.
Operating temperature: -40°C to +125°C (suitable for typical high-temperature operating conditions of the equipment)
Environmental Compliance: All materials comply with RoHS and REACH standards, and the manufacturing process is lead-free.

Customized Services

We offer end-to-end, customized high-current terminal harness services, providing the following tailored solutions to meet your equipment requirements:

Customizable wire diameter, length, and current-carrying capacity to meet the current‑transmission requirements of various devices.
Targeted optimization of terminal aperture and material (tin‑plated / nickel‑plated / silver‑plated) to match bolt specifications and corrosion‑resistance requirements.
Customized compatibility of insulation materials and temperature‑resistance ratings to meet diverse operating conditions, such as high‑temperature and humid environments.
We offer mass production and rapid prototyping services, along with comprehensive wire harness selection, test reports, and current‑load verification, helping customers efficiently develop high‑current connection solutions for their equipment.

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