High Voltage wire harness

We offer you the most advanced and durable high-voltage wire harnesses for the best performance. The harnesses are manufactured with the most durable quality materials.

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Product Introduction

Our high-voltage wire harnesses are especially designed to transfer the most accurate type of signals and the energy level. The core of the harness is built with the most durable and flexible copper type to keep the quality high. The harnesses have the most durable and flexible type of outshell to keep the machine secure. We carefully sealed every harness, stars and ends to resist dirt and other harmful elements. To keep the control system secure and working perfectly, these harnesses are covered with flexible and hard materials. These harnesses can also resist the quick shock and high electricity at the same time. The harnesses are carefully tested before shipping them to you. The cables and the materials are perfectly added to the harness for longevity.

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Product Advantages

Built for Safety and Long Life

We manufacture our EV harnesses to keep the machine safe and working smoothly. Every harness is carefully tested and connected to the parts. We use the materials that keep the harness and the core safe from harmful materials. Our harnesses are made especially for tough weather. The parts are designed to keep the machine running without any errors, and the backup design keeps the harness ready for hard situations.

Smart Design for Better Efficiency

We also design our high-voltage wire harnesses to save energy and make cars last longer. The wires are made to the exact size to carry electricity with minimal waste. This keeps them cool and helps the car go farther on the same charge. The cables are light but strong, which helps make the car faster and more efficient. Some high-voltage wire harnesses even have tiny sensors built inside to watch the temperature and voltage. These sensors help stop problems early before they become serious. With this innovative design, electric cars run smoother, safer, and with less energy loss.

Customized for Every EV Maker

We understand that every car maker is unique, so we create custom harnesses tailored to each customer. If you require a special connector, a different length, or a unique layout, we can accommodate your needs. We use trusted parts from reputable brands like Amphenol, TE Connectivity, and Yazaki, ensuring our high-voltage wire harnesses fit perfectly with other EV systems. Our engineers utilise 3D design tools to ensure that each harness fits neatly into tight spaces. We design for both small electric cars and large electric buses. Our goal is to create high-voltage wire harnesses that work perfectly today and are ready for tomorrow's technology.

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Material Recommendation

EV High-Voltage Wire

We use soft copper wires composed of many thin strands, allowing them to bend easily while carrying strong power. They are covered with XLPE, TPU, or silicone to protect from heat and wear. These wires can safely take 600 to 800 volts. Copper wire can provide stronger power to high-voltage wiring harnesses. All cables comply with the highest global safety standards and are coated with tin to prevent rust.

Corrugated Tubing

We use strong plastic tubes made of PP or PA to protect wire groups. These tubes are resistant to damage from heat, oil, and sunlight. For outdoor or tough use, we use thicker and fire-safe tubes. Some tubes have a slit for easy setup, while others are entirely closed to keep out dust and water. We secure them with clips and seals to ensure they stay tight. This keeps the wires neat, clean, and safe for years to come.

Heat Shrink Tubing

The 3M tubes are the best for the shrinking we use for your tubing. These tubings prevent the harmful elements from entering the harness. In these sealings, there are also extra layers for protection with glue. For the smooth and tight seals, the tubes are heated exactly. For easy recognition, we use color-shrinking tubes on the harnesses.

Connectors

We use the specially made connector that is best for the harnesses. Each harness has connectors that are easy to connect and durable for long lasting use. We also provide customized options for the specially built-in lock systems. The connectors are also available in both metal and plastic. The connectors are tested and carefully attached to the wires.

Copper Lug Terminals

The Copper lugs are coated with tin, which keeps the rust away. The join of the wires with the lugs is fine and tightly made. The busbars are sometimes used for better connection. Every harness is designed carefully to keep the machine running perfectly. For the best performances they are tested before applying.

Solution

The high-voltage harness systems we produce are suitable for all types of vehicle systems. We have a qualified and responsive team that helps you in every step of creating the harness. We carefully listen to all the details from you and understand it. After that, we start the whole manufacturing process.

EV Cable Cross-Section

If you cut one of our cables and look inside, you would see how it's built layer by layer. In the middle, there's a thick copper wire made of many small strands that carries power smoothly. Around it is a layer of XLPE that keeps power safe up to 800 volts. On top of that is a fine copper mesh that stops signal noise. Then comes a thin layer of aluminium foil for added protection. The outer part is made of soft rubber or TPU, which protects the wire from oil, heat, and scratches. Sometimes, we add one more thin coat to keep away salt or rust. This whole design keeps the wire safe, quiet, and strong. It can bend easily and fit in small places while still carrying power safely and smoothly.

High-Voltage Interconnection Harness

This harness is like the main power road inside an electric car. It connects major components, such as the battery, inverter, converter, and motor, together. It features thick wires for power and small cables for signals, all in a single, clean setup. We use strong and flexible connectors that are easy to plug in. Many harnesses also have safety plugs and fuses to prevent damage if the power becomes too high. We add shields and ground wires to block noise that might mess up sensors. Each harness is made to handle heat, water, and vibration without breaking. When it's done, it looks neat, works well, and can be used right away.

Automotive Power Harness

Our power harnesses distribute power to various car components, including the heater, air conditioner, charger, and inverter. Each harness uses strong wires that can handle 600 to 800 volts of power. We plan the wire paths carefully to prevent them from overheating and ensure that power flows evenly. Some of our designs use two wires for one line to stay cool and last longer. We test each layout to ensure it works safely and smoothly, even in tight or high-traffic areas. The connectors lock tightly in place and keep out water. In areas with high levels of movement or shaking, we use additional clamps and guards to protect the wires. These harnesses are built to last, easy to check, and simple to fix if needed.

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Industries and Applications

Electric Cars

Our high-voltage wire harnesses connect EV batteries, motors, and chargers. They make charging faster, driving smoother, and safer. EVs have the most advanced power and signal transferring system, which needs different types of harnesses. These harnesses are the best solution for transferring energy and signals smoothly from one part to another accurately.

Trucks and Buses

We make harnesses for heavy vehicles that use electric or hybrid power. They can handle high heat and long hours on the road. These kinds of vehicles need the most accurate and durable type of harnesses for excellent performance. These harnesses are made with the most durable and accurate, and best quality material.

Energy Systems

Our high voltage wire harnesses link power parts in solar, wind, and battery systems. They keep energy steady and clean. For the error free energy supply, these sectors need high quality harness cores with the exact type of connector. The harnesses are also equipped with the most durable shielding technology, which keeps the machine safe.

Factories and Machines

We manufacture harnesses for robots, forklifts, and other machines used in factories. They move both power and signals safely and smoothly. These harnesses are used in the most vital types of machines and industrial sectors to keep productivity smooth.

Trains and Heavy Vehicles

Our harnesses are used in trains and machines. They resist heat, dirt, and shaking and stay strong for years. For many years, these harnesses keep the vehicle running smoothly and finely. These heavy vehicles always require the most error free power and signal transferring system for safety.

Aerospace and Defense

We design and manufacture lightweight and strong harnesses for many essential tools in this sector, such as drones, armored vehicles, etc. They work safely even in very hot or cold places, and it meets the requirements of military and navigation standards. These harnesses are especially designed for these sectors.

Our Smart Manufacturing and Shipping Process

Engineering & Design

We start with innovative digital tools to make clear and strong designs. Our team creates 3D models. We test every wire, plug, and connector before building anything. Each material must pass strict safety checks. This early care helps our wire harnesses function properly, remain safe, and last for many years. We also ensure that each design meets the customer's specific needs. Every detail is carefully checked and rechecked to ensure perfection.

Automated Fabrication

When the design is ready, our machines take over the work. These intelligent robots cut, strip, and connect wires fast and clean. They work with great care to ensure each wire is in the correct place. Sensors monitor every move to detect even the most minor issues. Each joint is tight, smooth, and neat. This system saves time, reduces waste, and maintains the same high quality for every product. The final harness is strong, safe, and ready for heavy work in any condition.

Quality Inspection

Our quality team thoroughly checks every step to ensure there are no mistakes. We utilize cameras and sensors to identify minor issues that humans might overlook. Each harness is tested for power, heat, and strength. Every single one gets its own code, so we can track it later. This helps us stay clear, careful, and confident. We want every harness to be perfect before it leaves the line. We believe quality means trust, and we never skip a step.

Environmental Testing

We test the harness before shipping it to you in the real atmosphere. We test them to ensure that they resist all the tough situations. The harnesses are tested in many types of rigid weather to ensure durability. We select the harnesses that are eligible for your project. These tests are the most essential step to ensure durability. Each harness is carefully manufactured according to your design.

Packaging and Logistics

If the harness passes all tests, then we start the packing process. We use the most durable materials for the covers. Then we level the harness so that you can easily find the product for the project. The shipping team carefully delivers the product to you. We ensure that the product is exactly as you ordered. You do not need to do any manual work after receiving your product.

Thermal and Voltage Management Innovation

Our harnesses feature intelligent systems to regulate heat and power. Tiny sensors monitor the flow of power and measure its temperature. If the high voltage wire harness feels too hot or too tight, it automatically turns off to ensure safety. We use more than one wire to spread power evenly. Strong layers of insulation stop high voltage from leaking out. Even with very high power, the harness stays calm, safe, and steady. This means fewer risks and a longer life for every product.

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Advanced Shielding Against EMI and Electrical Noise

Electric vehicles need smooth power with no noise. If wires pick up outside signals, it can cause problems. To prevent this, we wrap the wires with two strong shields, one made of copper braid and one of foil. These layers block bad signals and keep the power clean. Together, they stop almost all electrical noise. This helps motors run smoothly and sensors stay clear. The car's systems remain calm and safe, with no power loss or mix-ups.

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Safety Beyond Standards

We carefully follow all the safety rules to manufacture the  high voltage wire harnesses. We follow rules like ISO 6469 and ISO 26262 and more. To resist the harmful situations in the connection we test each part according to the safety standards. We always avoid the cheap quality materials in manufacturing. The connectors we use in the harness are top-grade. They prevent fault connections and resist sparking.

Future-Ready Engineering for Smart Technology

Our high voltage wire harnesses are made for the future. Modern cars use 5G, intelligent systems, and sensors, and our designs are ready for all of it. We add extra spaces and plugs for easy upgrades. They can carry both power and data simultaneously. This makes them perfect for new electric and self-driving cars. We want our customers to grow and upgrade without worry. Our designs stay strong and ready for whatever comes next in the tech world.

Custom Projects We've Completed

There are a large number of projects we have handled with accuracy. We designed the harnesses for many vehicles and machines. We have handled projects of different sizes and numbers. We are the most responsive and experienced team for your project. There are a large number of happy clients pleased with our professional and friendly service. The projects we handled all are done with the most accuracy and efficiency.

Partner with Innovation: QL-Custom Technology

When you choose QL-Custom Technology, you select a team that cares about quality and trust. We utilise advanced tools, robots, and rigorous testing to ensure each high voltage wire harness is both strong and safe. We promise quick answers, fast delivery, and full support. Whether you need one sample or a large order, we're ready to help. Every harness we make demonstrates our commitment to care, safety, and innovation. Work with QL-Custom and bring your innovative ideas to life with confidence and strength.

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Customer Reviews

Fast delivery and great performance. The wires and connectors looked very strong. We are very happy with the service and help.

Michael Chen

The shielding worked perfectly! No noise problems at all. Great design and great support from start to end.

Dr Angela Martínez

No defects, fast shipping, and top build quality. The harness still works great after long use.

Marcus Lee

Perfect fit and very safe to use. The 3D drawings helped us plan fast. Thanks to the QL team for great support!

Sarah O'Neill

Every wire matched our design perfectly. Great team, great quality, and smooth delivery.

David Wilson

Helpful team and quick replies. The whole process was simple, easy, and fast from start to finish.

Laura Schmidt

Promise Reply in 4 hours !








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