①——Automobile Wire Harness – Custom & Wholesale Wire Harnesses

Automobile Wire Harness

Why Choose Us?

KABOLUX has an extensive track record in the automotive sector, with a deep understanding of automotive wire harness design and manufacturing standards.

We offer fully customized solutions, ensuring our products meet the unique specifications of different vehicle models and applications.

Leveraging cutting-edge equipment and a stringent quality control framework, we deliver automotive wire harnesses that are both high – performing and dependable.

International standard

Dimensional Specifications:

Harness Types and Dimensions: According to the ISO 19642 series of standards, the dimensions of automotive cables are specified for different voltage levels, number of cores, and materials. For example, ISO 19642.4-2019 applies to single-core aluminum core cables for 30V AC or 60V DC; ISO 19642.5-2019 applies to single-core copper core cables for 600V AC or 900V DC, as well as 1000V AC or 1500V DC.

Main and Branch Harness Dimensions: Based on the Q-FT B205-2014 specification, exposed harness mains are required to be wrapped with corrugated tubing. For harness mains up to 2000mm in length, the length tolerance is +10mm, and for branches, it is +5mm; for mains over 2000mm, the length tolerance is +15mm, and for branches, it is +10mm.

Material Specifications:

Conductor Material: Typically, multi-strand braided soft bare copper wires are used, in accordance with ASTM B174 requirements.

Insulation Material: Common types include cross-linked polyethylene insulation and PVC insulation. For example, low-voltage cables with cross-linked polyolefin insulation have a working temperature of +125°C; thick-walled thermoplastic polyvinyl chloride insulated wires have a working temperature of +80°C.

Protective Materials: For chassis harnesses, PVC corrugated tubing with a wall thickness of ≥0.8mm is used, which is resistant to oil and acid-alkali. For high-voltage harness insulation layers, special materials are used to meet high-voltage requirements.

Fixing Process Specifications:

Fixing Point Layout and Spacing:
- For low-voltage body harnesses, the fixing point spacing should be ≤400mm, with a distance from moving parts of ≥30mm and a distance from heat sources of ≥100mm.
- For high-voltage power harnesses, the fixing point spacing should be ≤300mm, with a distance from moving parts of ≥50mm and a distance from heat sources of ≥200mm.
- For chassis harnesses, the fixing point spacing should be ≤350mm, with a distance from moving parts of ≥20mm and a distance from heat sources of ≥150mm.

Tie Wrap Operations:
- The remaining length of the tie wrap end should be ≤3mm, with a tilt angle of ≤15°.
- The clamping force for low-voltage harnesses is 20N-40N, and for high-voltage harnesses, it is 50N-80N.

Product Benefits

Our automotive wire harnesses are crafted from premium materials, guaranteeing superior electrical and mechanical performance.

They are rigorously tested across electrical, mechanical, and environmental parameters to ensure unwavering performance in diverse conditions.

Additionally, these harnesses are designed with robust electromagnetic compatibility, minimizing interference with other automotive electronic systems and ensuring seamless vehicle operation.

Full - Chain Technical Capability:

Self – developed AI Wiring Algorithms: Our AI – based algorithms optimize wiring topology, reducing redundant wire lengths by up to 30%.

High – Voltage Harness Reliability: Our high – voltage wire harnesses have a 100% pass rate in ISO 6722 voltage – withstand and salt – spray tests (exceeding 1000 hours).

Cost - Control Advantage:

Scale – based Procurement Agreements: We secure copper materials at costs 12% – 18% lower than market rates (offering price – volatility hedging solutions).

Modular Design: This approach minimizes material waste and optimizes overall costs by up to 25%.

Quality Assurance System:

Stage	Control Standard	Certification Support
Raw Materials	Spectral analysis + batch traceability	UL, RoHS, REACH
Production	AOI visual inspection + real - time SPC monitoring	IATF 16949, AS9100D
Final Testing	30kV withstand voltage + eye - diagram signal integrity analysis	ISO 6469 - 3 (short - circuit safety)

Product Categories

KABOLUX’s automotive wire harness product line ranges from engine, body, and chassis harnesses to interior ones.

These harnesses ensure precise signal transmission for engine performance, integrate electrical systems for driving comfort, enhance chassis stability and safety, and offer reliable connections for an enhanced in – cabin experience.