Overview
Alongside standard body and powertrain wiring, XinHarness builds high-voltage interconnect and power distribution harnesses for hybrid and full-EV battery systems, covering module-to-module busbar links, pack-to-inverter cabling, and low-voltage BMS signal harnesses on the same platform.
Design & Construction
High-Voltage Conductors
Power conductors run 4 AWG to 20 AWG with silicone or XLPE insulation rated to 125°C, sized to the pack’s continuous and peak current draw. Orange high-voltage jacketing and labeling follow SAE J1673 color and marking practice.
Busbar & Lug Terminations
Copper lugs and busbar interfaces are torque-controlled and crimp-force monitored, with dielectric boots and IP67-rated sealing at the battery-side connector interface to protect against moisture and debris ingress in the pack enclosure.
Manufacturing Process
Assemblies are built on IATF 16949-certified lines with PPAP documentation and 100% hipot and insulation-resistance testing before release, consistent with the process controls we run across our automotive production floor.
Typical Applications
- EV/HEV battery module interconnects
- Pack-to-inverter and pack-to-charger power cabling
- Battery management system (BMS) signal harnesses
- DC-DC converter and onboard charger wiring
- High-voltage junction box assemblies
Quality & Certification
Production runs under our IATF 16949-certified, ISO 9001 quality system, with the same PPAP and APQP process discipline applied to our general automotive harness lines. Insulation-resistance and hipot test records are retained per unit for full traceability.
Why XinHarness
Our automotive lines are sole-source qualified by several Tier-1 suppliers across Europe, North America, and Asia, and increasingly support ICE, hybrid, and full-EV platforms on shared tooling. See our full capability on the Automotive industry page, or reach out from the homepage to discuss a battery harness drawing.
