The New Energy Wire Harness Manufacturer!

 

At COCENTRA, we will continue to uphold the principle of "Innovation, Quality, and Service First," focusing on the needs of our customers and continuously improving our products and services. We strive to be your trusted, long-term partner in connectors, cable assemblies, and antenna solutions.

 

 
  • AC Harness
    Key Features. Matched Pair Solution. Female (CATS230-049) + Male (CATS090-050) connectors. High-Current AC Rating. 600V AC / 42A continuous (10AWG recommended)
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  • DC Harness
    Key Features. Stäubli MC4 Certified. Fully compliant with IEC 62852 & UL 6703 standards. Dual-rated voltage: 1000V DC (IEC) / 1500V DC (UL)
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  • Switch Harness
    Key Features. GHX5 Series Isolator Switches. 1000V AC rated voltage for solar applications. Panel-mounted (P-type) with dual IP ratings
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  • Communication Harness
    Key Features. Industrial D-SUB Connector. YLK waterproof 9-pin female (solder type). 2500+ mating cycles for long-term reliability
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  • Button Harness
    Key Features. Vandal-Resistant Metal Switch. ONPOW LAS1GQ series stainless steel button. 50,000+ operation cycles
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  • Socket Harness
    Key Features. Military-Grade Aviation Socket. YF M25 series panel-mount socket (solder type). 3000+ mating cycles for field durability
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  • Thermistor Assembly Harness
    Key Features. Precision Temperature Sensing. EXSENSE BT series NTC thermistor. 10KΩ±1% @25°C with B3950K±1% curve
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  • Battery Cable Harness
    Key Features. Dual-Purpose Configurations. Charging Ports: 5PIN 2P3S (6A power + 2A signal). Discharge Ports: 2P4S (30A power + 2A signal, expandable to 4P8S)
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why choose us
 
 
 

Expertise

With over ten years of experience and a specialized R&D team, we offer industry-leading solutions backed by years of technological innovation.

 
 

Production Equipment

With our connector lab and antenna lab, we are dedicated to delivering highly competitive products that help our clients enhance their market competitiveness.

 
 

Product Quality Guarantee

All our products undergo rigorous testing and meet international standards, including ISO9001, ISO14001, IATF16949, and QC080000 certifications. We are responsible for the quality of every connector, cable assembly, and antenna solution.

 
 

Product Customization

We provide tailored solutions, including small-batch production and custom connectors. Our technical team ensures the products meet your exact specifications.

 

 

Advantages of wiring harnesses for new energy vehicles

Highly efficient transmission of electrical energy and signal data

New energy vehicle wiring harnesses connect various electrical devices inside the vehicle through fine design and layout, realizing the interconnection of electrical energy and signal data. Power harnesses are mainly used to transmit high-current electrical energy, connecting key components such as electric motors, batteries and charging devices to provide power drive for electric vehicles. The signal harness is used to transmit low-current signal data, connecting various sensors, controllers, and in-vehicle electronic devices to realize communication and control between vehicle components. This efficient transmission ensures the normal operation and precise control of the vehicle.

Protecting wires and connectors

New energy vehicle wiring harnesses utilize high-quality insulating materials and connectors that can effectively protect wires and connectors from damage in harsh environments. These materials have good weather and abrasion resistance, and can withstand adverse factors such as vibration, temperature changes and humid environments during vehicle operation, thus extending the service life of the wiring harness.

Button Harness
DC Harness

Simplified Installation and Maintenance

The prefabricated and standardized design of wire harnesses for new energy vehicles makes them easy to install and maintain. The modular design of the wiring harnesses makes the installation process easier and faster, improving productivity. At the same time, standardized interfaces and connectors also facilitate subsequent repair and replacement work, reducing maintenance costs.

Improve the reliability of the system

New energy vehicle wiring harnesses are reasonably designed and wired in an orderly manner, which can effectively reduce electromagnetic interference and mechanical damage, and improve the reliability and stability of the system. Reasonable wiring design can also reduce the length and complexity of the line, reduce energy loss and signal attenuation, thereby improving the performance of the entire electrical system.

 

Testing of New Energy Wire Harness
 

Electrical Continuity Testing

Electrical continuity testing ensures that every connection in the harness is intact and capable of carrying the required current without fail. Continuity checks are essential for verifying the wiring and ensuring no open circuits or broken connections in the harness.

Thermal Stress Testing

Thermal stress tests simulate extreme temperatures to ensure that high-quality EV wiring harnesses can withstand the thermal fluctuations that occur in real-world conditions. These tests ensure the insulation materials don't degrade over time due to heat and that the wiring continues to function efficiently.

Vibration and Mechanical Testing

Vibration and mechanical stress tests verify that the harness can survive the dynamic environment of an electric vehicle. These tests simulate the vibrations and physical forces the wiring harness will encounter throughout its service life.

Environmental Durability Testing

Environmental testing evaluates the harness's resistance to moisture, chemicals, UV radiation, and other environmental factors. These tests simulate the real-world conditions the harness will be exposed to during the vehicle's operational lifetime.

 

Application of New Energy Wire Harness
 

Aerospace. Wire assemblies are used in an expansive range of aerospace products, such as drones, satellites, and aircraft to facilitate the transmission of power, communication, and more.

 

Automotive. Wire harnesses are critical for saving valuable space within automobiles within the dashboard, under the hood, lighting/signals, and more. They are also important for organizing complex wiring in such a way that technicians can easily identify their purpose.

 

Medical. Hospitals and clinics rely on wire harnesses to organize and protect wires in and between equipment, including crash carts, diagnostic and imaging equipment, dental equipment and more.

 

Telecommunications. Wire harnesses optimize use of space in a variety of telecommunications equipment, such as modems, routers, repeaters, and a variety of other communication and broadband equipment.

 

Information technology. Nearly all computers, laptops, servers, and other IT technology contain wire harnesses to optimize space and organize wires for easy identification and installation by technicians.

 

Construction. Wire harnesses are widely used within structures to provide wiring insulation and organization.

 

Manufacturing. CNC machines and other powered manufacturing equipment rely on wire harnesses to route and organize external and internal wiring.

 

Robotics and automation. Wire harnesses are used on most automated equipment and robotics to safely route, group, and protect critical wiring.

 

Wire Harness Components and Materials Used in Manufacturing

 

Wire harnesses consist of various components and materials in the manufacturing process. The most common elements include wires, connectors, terminals, and protective sleeves. Wires are typically made from copper or aluminum and are coated with insulation to prevent electrical interference. Connectors join wires and come in various shapes and sizes depending on the application. Terminals are attached to the wire ends to connect them to other components. Protective sleeves to cover the cables provide additional protection from heat, moisture, and other environmental factors.

 

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The materials used to manufacture wire harnesses can vary depending on the application and harness assembly requirements. Common materials include PVC, polyethylene, and polypropylene for insulation and nylon or polyester for protective sleeves. With specific applications where high temperatures or extreme environmental conditions are a concern, using more advanced materials such as Teflon or silicone is common.

 

FAQ

 

Q: Why is the wiring harness important in the automotive industry?

A: Cars today are equipped with electronic components that, in addition to the basic operations of moving, turning, and stopping, perform various other functions as well. Wiring harnesses are indispensable in controlling these electronic components, transmitting power and signals to every part of the vehicle.

Q: What is the best wire for automotive harness?

A: Automotive primary wire, often referred to as GPT wire, is the industry standard for general circuit wiring in vehicles and light-duty trucks. It uses stranded copper conductors for flexibility and a durable PVC insulation to protect against heat, abrasion, and harsh chemicals commonly found in engine compartments.

Q: Will a car run without a wiring harness?

A: In most cases, a car will not start without a working cable harness. It represents a critical component of a vehicle's electrical system, connecting various electrical components such as the battery, alternator, starter motor, and ignition switch.

Q: What is the ISO standard for wiring harness?

A: The ISO standard for wiring harnesses is primarily ISO 8092-5 for road vehicles, which covers test methods and general performance requirements for wiring harness connector operation. Additionally, ISO/TS 10303-1828 focuses on the product data representation and exchange for wiring harness assembly design, including components like connectors, terminals, and splices. The IPC/WHMA-A-620 standard, though not strictly an ISO standard, is also widely used in the industry for cable and wire harness assembly requirements and acceptance.

Q: What is the IPC for wire harness?

A: The IPC 620 standard plays a crucial role in ensuring the quality, reliability, and consistency of cable and wire harness assemblies. By providing a common set of acceptance criteria, it helps manufacturers: Maintain consistent quality standards. Reduce manufacturing defects and rework.

We're professional new energy wire harness manufacturers and suppliers in China. If you're going to wholesale customized new energy wire harness, welcome to get quotation from our factory. For price consultation, contact us.

Button Harness, Switch Harness, Thermistor Assembly Harness
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