High Voltage Wiring Harness | Custom EV HV Harness Solutions - Ouketech
Ouketech provides IATF 16949 certified custom high voltage wiring harnesses for electric vehicles, renewable energy, and industrial applications. 20+ years of engineering expertise, end-to-end solutions, and rigorous quality testing.
High Voltage Wiring Harness: Custom Engineered Power Distribution Solutions
As a leading custom wiring harness manufacturer with 20+ years of industry experience, Ouketech designs and manufactures high voltage wiring harness solutions engineered to deliver safe, reliable power transmission across the most demanding operating environments. Our HV harnesses are purpose-built for electric vehicles, renewable energy systems, industrial automation, and medical equipment, meeting the strictest international safety and performance standards.
The Critical Role of High Voltage Wiring Harnesses
High voltage wiring harnesses serve as the central nervous system of modern high-power applications, carrying electricity at voltages ranging from 300V to 1000V between critical system components. Unlike conventional 12V/48V low-voltage harnesses, HV assemblies require specialized design, materials, and manufacturing processes to withstand extreme electrical stress, temperature fluctuations, vibration, and environmental exposure.
The global transition to electric mobility and renewable energy has driven exponential demand for high-performance HV harness solutions. Electric vehicles alone require 5-7 distinct HV harness assemblies to connect battery packs, motors, inverters, charging systems, and auxiliary components. These harnesses must maintain 100% reliability over 10+ years of vehicle operation while withstanding temperatures from -40°C to 200°C, continuous vibration, and exposure to oils, chemicals, and moisture.
Our engineering team understands the unique challenges of HV system design. We work directly with your R&D and procurement teams from the earliest design stages to develop harness solutions that optimize power efficiency, reduce weight, simplify installation, and minimize long-term maintenance costs.
Comprehensive HV Harness Solutions for Every Application
Ouketech offers a complete portfolio of 9 specialized high voltage wiring harness product lines, fully customizable to your exact specifications:
Our EV-specific high voltage wiring harnesses are engineered for passenger cars, commercial vehicles, off-highway equipment, and electric two-wheelers:
- Connect high-voltage battery packs to traction motors and inverters, supporting 400V and 800V architectures with current ratings up to 600A
- Optimized dual-layer shielding minimizes electromagnetic interference, meeting strict automotive EMC requirements
Purpose-built for both on-board and off-board charging applications:
1、On-board Charging Harnesses: Connect charge ports to on-board chargers and battery management systems, supporting Level 1, Level 2, and DC fast charging
2、DC Fast Charging Cable Assemblies: High-current 1000V harnesses for charging station infrastructure, with liquid-cooled options for 500A+ continuous operation
Compatible with all global charging standards including CCS, CHAdeMO, NACS, and GB/TIP69K rated connector assemblies for reliable outdoor operation in all weather conditions
Designed for residential, commercial, and grid-scale battery storage installations:
String Harnesses: Connect individual battery modules into series strings, with integrated voltage and temperature sensing
DC Bus Harnesses: High-current power distribution between battery racks, inverters, and grid connection points
Low-Voltage Control Harnesses: For BMS communication, control, and monitoring systems
Fire-resistant and flame-retardant materials meet UL 94 V-0 standards for energy storage applications
Solar Photovoltaic (PV) HV Harnesses
UV-resistant harness solutions for solar installations of all sizes:
PV String Harnesses: Connect solar panels in series strings, with pre-terminated MC4-compatible connectors
Array to Inverter Harnesses: High-voltage DC power transmission from solar arrays to central or string inverters
Rated for 25+ year outdoor exposure, with resistance to UV radiation, extreme temperatures, and moisture
Wind Turbine HV Harnesses
High-reliability harnesses for onshore and offshore wind turbine applications:
Nacelle Harnesses: Power distribution between turbine generator, converter, and control systems
Tower Harnesses: High-voltage power transmission down the turbine tower to grid connection points
High-flex design withstands continuous vibration and torsional movement over 20+ year operational life
Low-temperature materials suitable for operation in extreme climate conditions down to -40°C
Rugged high-voltage solutions for industrial manufacturing environments:
Robot Arm Harnesses: High-flex, continuously moving HV harnesses for 6-axis industrial robots and cobots
Heavy Machinery Harnesses: Power distribution for construction, mining, agricultural, and material handling equipment
Factory Automation Harnesses: HV power for conveyor systems, packaging equipment, and automated production lines
Oil and chemical resistant materials suitable for harsh industrial operating environments
Lightweight, high-reliability high voltage interconnects for aerospace applications:
Electric Aircraft Harnesses: HV power distribution for electric propulsion systems in eVTOL, commercial, and military aircraft
UAV/Drone Harnesses: Ultra-lightweight HV harnesses for unmanned aerial vehicle propulsion systems
Defense Systems Harnesses: HV solutions for military vehicles, radar systems, and directed energy weapons
Meet DO-160 and MIL-STD environmental and performance requirements
Our medical wire harness solutions include high-voltage interconnects for diagnostic and therapeutic medical devices, meeting ISO 13485 medical device quality standards:
Diagnostic Imaging Harnesses: HV power for X-ray, CT, MRI, and PET scanning systems
Therapeutic Device Harnesses: High-voltage solutions for defibrillators, electrosurgical equipment, and radiation therapy systems
Low-noise design ensures no interference with sensitive medical instrumentation
Biocompatible materials available for patient-contact applications
Marine & Offshore HV Harnesses
Corrosion-resistant high voltage harnesses for marine and offshore applications:
Electric Vessel Harnesses: HV power distribution for electric and hybrid ships, ferries, and workboats
Offshore Platform Harnesses: Power transmission for oil and gas platforms, offshore wind farms, and subsea equipment
IP68 rated for continuous
Guide
Technical Specifications & Material Selection Guide
Conductor Material
Sizes Available
Applications
Tinned Copper
0.13mm² – 300mm² (26AWG – 350MCM)
General purpose, high conductivity
Aluminum
10mm² – 300mm²
Lightweight applications, cost-optimized designs
Material
Temperature Range
Recommended Applications
Cross-Linked Polyethylene (XLPE)
Cross-Linked Polyethylene (XLPE)
-40°C to 150°C
High mechanical strength, excellent chemical resistance
Under-hood automotive, industrial systems
Silicone Rubber (SIR)
-60°C to 200°C
Exceptional flexibility, small bending radius, high temperature resistance
High-heat environments, tight installation spaces
Thermoplastic Elastomer (TPE)
-40°C to 125°C
Cost-effective, good abrasion resistance
General purpose, large-format cables
- Single Layer Braided Shield: 90%+ coverage tinned copper braid for low-frequency EMI protection
- Dual Layer Shield: Aluminum foil + tinned copper braid for combined high/low frequency EMC protection, meeting ISO 14572 requirements (transfer impedance ≤ 31mΩ/m, shielding attenuation ≥ 70dB)
- Unshielded: For low-EMI environments where interference is not a concern
Service Advantages: The Ouketech Difference
With two decades of experience in custom cable assemblies and high voltage interconnect solutions, Ouketech delivers end-to-end value at every stage of your project:
01
End-to-End Custom Engineering Support
02
Advanced Manufacturing Capabilities
Our state-of-the-art manufacturing facilities feature:
- Automated cutting, crimping, and terminal processing equipment with 100% crimp force monitoring
- Precision magnetic pulse crimping technology for large-diameter cables up to 300mm², creating ultra-reliable, corrosion-resistant connections with zero relaxation over thermal cycling
- Cleanroom assembly areas for medical and aerospace applications
Vertical integration including in-house extrusion, molding, and tooling capabilities
We support production volumes from 10-unit prototype runs to 100,000+ unit mass production, with flexible manufacturing lines that can quickly scale to meet your changing production requirements.
03
Rigorous Quality Control & Testing
Every high voltage wiring harness we manufacture undergoes
- comprehensive testing to ensure 100% reliability:
Electrical Testing: Hi-pot (withstand voltage) testing up to 5kV, insulation resistance testing, continuity testing, and contact resistance measurement - Environmental Testing: Thermal cycling from -40°C to 200°C, vibration testing, humidity testing, salt spray testing, and IP ingress verification
- Mechanical Testing: Tensile strength testing, crimp pull testing, bend cycle testing, and abrasion resistance testing
- Material Testing: Flame resistance testing (UL94 V-0), chemical resistance testing, and material composition verification
We maintain 100% part traceability for every component in our harnesses, with full documentation packages available for quality and compliance purposes. Our facilities are certified to IATF 16949, ISO 9001:2015, standards.
04
Supply Chain Reliability & Competitive Lead Times
We understand the critical importance of on-time delivery in today’s fast-paced manufacturing environment:
- Standard lead times: 4-6 weeks for production orders
- Expedited prototyping: 1-2 week turnaround for custom prototype harnesses
- Strategic component inventory management to mitigate supply chain disruptions
- Minimum order quantities (MOQs) starting at just 10 units for custom designs
Ouketech's engineering team is ready to partner with you to develop the perfect high voltage wiring harness solution for your application.
Whether you need a simple prototype harness or a fully optimized mass production solution, we have the expertise and capabilities to deliver exceptional quality and value.
Contact our sales team today to discuss your requirements, request a quote, or schedule a technical consultation with our engineering team. We typically respond to all inquiries within 12 business hours.
Looking for other interconnect solutions? Explore our full range of custom cable assemblies, industrial cable assembly, and automotive wiring harness solutions.
Common Questions (FAQ)
What is the maximum voltage and current your harnesses can support?
Our custom HV harnesses can be designed to support voltages up to 1500V DC and currents up to 600A, depending on conductor size and material selection. Our engineering team will work with you to specify the exact configuration for your power requirements.
Can you manufacture harnesses based on our existing designs and specifications?
Yes. We support both full custom design from scratch and build-to-print manufacturing based on your existing drawings and specifications. Our engineering team will conduct a full design review to identify any potential manufacturing or performance optimization opportunities before production begins.
Do you offer overmolded cable designs for harsh environment applications?
Yes. Our custom overmolded cable assemblies provide enhanced environmental protection, strain relief, and tamper resistance for applications requiring IP67/IP69K protection. We offer a range of overmold materials including PVC, TPE, and engineering-grade plastics.