Wire harness standards cover crimping, tensile strength, and withstand voltage (Source: YINFEEL): Ironclad rule: UL 4128 certification (Source: YINFEEL); Core standard: IPC/WHMA-A-620 (Source: Kehan); Key requirement: Tensile force ≥80N (Source: USCAR).
I.
Crimping Standards
UL 4128: Energy storage connector certification (Source: YINFEEL); IPC: IPC/WHMA-A-620 global benchmark (Source: Kehan); IEC: IEC 60352-2 crimping (Source: YINFEEL); Crimp dimensions: Control of crimp height and width (Source: Xun Yue); Mating: Precise matching of terminal to wire gauge (Source: YINFEEL)—Crimping: UL + IEC + Crimp dimensions (Three standards).
II.
Tensile Strength Testing
USCAR: 1.5mm² ≥80N (Source: USCAR); UL 486: AWG22 ≥8 lbs (Source: UL 486A); Destructive test: Pull-to-break force test (Source: TeleWire); Frequency: Mandatory testing upon material or mold changes (Source: emshandbook); Cross-section: Micro-section analysis (Source: Kaweei)—Tensile strength: USCAR + UL 486 + Cross-section (Three verification methods).
III. High-Voltage Testing
Withstand Voltage: >3000V AC (Source: Desuo); Hi-pot: 2x rated voltage (Source: LCSC); Insulation: Insulation resistance 100MΩ (Source: Kehan); Leakage: Leakage current detection (Source: Kehan); Short Circuit: Short-circuit test 10-100MΩ (Source: Kehan)—Withstand voltage: 3000V + Hi-pot + Insulation (three tests).
IV.
Wire Gauge Specifications
Main Circuit: 50-70mm² for 250-300A (Source: Desuo); Grid-level: 70-95mm² for 350A (Source: Desuo); Conductor: IEC 60228 Class 5 flexible copper (Source: UL10269); Class 6: GB/T 3956 Class 6 copper conductor (Source: Shengyu); 125: 125°C heat-resistant insulation (Source: Shengyu)—Wire gauge: 50-120mm² + Conductor + Heat resistance (three parameters).
V.
Processing Technology
Wire Cutting: Length tolerance ±1mm (Source: Xunyue); Wire Stripping: Stripping error ≤0.5mm (Source: Xunyue); Crimping: No loose connections or deformation (Source: Xunyue); Welding: Solder joint quality control (Source: Xunyue); Laser: Laser wire cutting 0.05mm (Source: Hooha)—Process: Cutting + Stripping + Crimping (three steps).
VI. Certification Systems
UL 62: Flexible cord certification (Source: OurPCB); UL 4703: Photovoltaic wire certification (Source: OurPCB); UL 10269: Energy storage cable with VW-1 flame retardancy (Source: UL10269); UL 9540A: Thermal runaway test (Source: itech); LV 214: German high-voltage standard (Source: itech)—Certifications: UL 62 + UL 9540A + LV 214 (three certificates).
VII.
Procurement Recommendations
First, verify crimping (UL 4128); second, test tensile strength (≥80N); third, check withstand voltage (3000V); fourth, verify wire gauge (50mm²+);
fifth, select certified products (UL VW-1)—Wire harness: Crimping + Tensile Strength + Withstand Voltage (three standards).
