New Energy High Voltage Harness | 1000V/300A Certified & Custom

The rapid acceleration of global electric mobility and renewable energy adoption has created an unprecedented demand for high-voltage interconnection systems that are safe, reliable, and efficient. At the heart of these systems lies the New Energy High Voltage Harness, a critical component that connects batteries, power electronics, and electric motors in vehicles, energy storage systems, and industrial machinery. As a leading manufacturer in China, we have invested heavily in R&D and production infrastructure to deliver cutting-edge high-voltage harness solutions that meet the evolving needs of our international clients.
Our production process begins with meticulous material selection. We source only certified copper conductors with tin-plated or silver-plated surfaces to ensure excellent conductivity and corrosion resistance. These conductors are available in various cross-sections, from 0.5mm² to 120mm², to accommodate different current ratings. For insulation, we utilize cross-linked polyethylene (XLPE), silicone rubber, or PVC compounds, each chosen for its specific thermal, dielectric, and mechanical properties. For instance, our silicone-insulated harnesses can withstand continuous operating temperatures of up to 180°C, making them ideal for high-temperature engine bays and battery compartments.
Our advanced manufacturing lines incorporate automated wire stripping, crimping, and assembly equipment. Every crimping operation is monitored by real-time quality sensors, ensuring consistent termination quality with a standard deviation of less than 0.1mm. We employ ultrasonic welding for certain high-current connections, achieving joint resistance below 20 micro-ohms, which minimizes power losses and heat generation. After assembly, each harness undergoes a series of stringent tests, including 100% high-potential (HIPOT) testing at up to 3500VAC, insulation resistance measurement, and continuity checks. For waterproof and dustproof applications, we perform IP67/IP69K testing to verify the sealing integrity.
Our commitment to quality is further demonstrated by our certifications. We hold ISO9001 for quality management, IATF16949 for automotive, ISO13485 for medical devices, and UL listing for various cable assemblies. Our testing laboratory is equipped with a thermal shock chamber that cycles from -40°C to +150°C, a vibration table that simulates vehicle operating conditions, and a salt spray tester for corrosion evaluation. These capabilities allow us to validate our products under rigorous conditions, ensuring they meet the demanding requirements of the global market.
In terms of global applications, our New Energy High Voltage Harness components are extensively used in electric vehicles, including passenger cars, buses, and trucks. For example, our flat cable assemblies are used in battery modules of a leading European EV brand, supporting a peak power output of 250kW with an efficiency of 98.5%. Our harnesses are also integral to energy storage systems that provide grid stability in countries like Germany and Australia, where renewable energy penetration is high. In these systems, our harnesses operate at 1500V DC and handle currents up to 500A, with a predicted service life of over 20 years in ambient temperatures ranging from -20°C to +50°C.
We understand that each customer has unique requirements, which is why we offer a full range of customization options. From connector selection (including HARTING, Amphenol, TE Connectivity, and our proprietary SurLok series) to cable length, color coding, and over-molding, we work closely with you to design a solution that perfectly fits your application. Our in-house prototype lab can produce functional samples within 3-5 days, allowing for rapid iteration and validation. For mass production, we utilize a dedicated production floor of 10,000 square meters, achieving a capacity of 5 million harness assemblies per year.
Moreover, we offer value-added services such as harness routing design, installation guidance, and after-sales technical support. Our team of 35 R&D engineers is available worldwide, with fluency in English and German, to assist with any technical challenges you might face. We pride ourselves on our responsiveness and flexibility, with a typical response time of 24 hours for queries and a 48-hour turnaround for quotes.
As a trusted partner for new energy high voltage interconnect solutions, we invite you to explore our comprehensive range of products and discover how our engineering excellence can enhance the performance and safety of your systems. Contact us today to discuss your specific requirements and experience the Nangudi difference.