High-voltage harness and connector manufacturing, 1000 V DC
Connectors, PDU/BDU power-distribution units and HV power looms built in the same plant — one of the few setups where the housing is moulded, the busbar is assembled and the loom is tested under one roof. 1,500,000 sets a year, IATF 16949, and our engineers co-authored the national HV connector specification.
Five in-house series cover 32 A to 250 A
One mechanical platform logic — two-stage tool-free release, integrated HVIL and a 360° shield — scaled from 2.5 mm² PTC circuits to 70 mm² motor feeds. Screen-printed series codes, your part number on the drawing.
| Series | Typical application | Positions | Wire range | Max current | Notes |
|---|---|---|---|---|---|
| 280B | Battery pack, DC/DC, PTC, A/C, slow charge to OBC | 2P / 3P | 2.5–4 mm² shielded | 32 A @ 80 °C (4 mm²) | One-piece HVIL, 2-stage tool-free release, 360° shield |
| 530 | Battery pack, DC/DC, PTC, A/C, OBC | 2P / 3P / 4P | 2.5–6 mm² shielded | 45 A @ 80 °C (6 mm²) | Split HVIL, three keying positions, 360° shield |
| 450 | Inverter, OBC, PDU, e-heater, e-A/C | 2P | 6–10 mm² shielded | 60 A @ 80 °C (10 mm²) | One-piece HVIL, panel or inline mounting |
| 1200 | Fast charge, PDU, battery pack | 2P, 180° / 90° exit | 16–25 mm² shielded | 120 A @ 80 °C (25 mm²) | One-piece HVIL, busbar-capable board end |
| 1800 | Motor, inverter, fast charge, PDU | 2P, 120° / 180° exit | 25–70 mm² shielded | 250 A @ 80 °C (70 mm²) | Ultrasonic-welded terminations, IP67 / IP6K9K |
The same envelope, every series
| Rated voltage | 1000 V DC |
|---|---|
| Dielectric strength | 3000 V AC |
| Insulation resistance | > 200 MΩ at 1000 V DC |
| Ingress protection | IP68 + IP6K9K (IP67 on the 1800 series) |
| Touch protection | IPXXB finger-safe |
| Working temperature | -40 °C to +125 °C continuous |
| Mating life | ≥ 50 cycles |
| Housing / flame rating | PA66+GF, UL94 V-0 |
| Shielding | 360° shield termination on shielded versions |
| Interlock | Built-in high-voltage interlock (HVIL) loop |
PDU, power looms and charging inlets
PDU / BDU units
Power distribution and battery disconnect units with SMT control boards, busbar assembly and hipot test in-house. Series-supplied to EV programmes today, including exclusive-supply positions.
HV power looms
Shielded 2.5–70 mm² power lines with ultrasonic-welded shield termination, braided sleeving and moulded breakouts, routed and 100% tested against the approved drawing.
Charging inlets
Combined fast/slow inlets and DC fast-charge sockets to GB/T 20234: 125–300 A DC, 32 A AC, 10,000 mating cycles, IP54/IP55, with PCB or loom exit.
Splitter / junction modules
One-in-two out HV junction modules, 15–50 A, crimp-and-pot construction with keyed panel clips.
Low-voltage harnesses
Full-vehicle body, chassis and dashboard looms on the same Komax / TSK line set — HV and LV built together is exactly how a modern EV is wired.
Programme support
Synchronous development with your electrical architecture, DFM feedback on housing and busbar design, PPAP-style documentation, ramp to volume.
Qualified against, and contributing to
| T/CSAE 178-2021 | EV high-voltage connector technical specification — our engineering team co-authored it |
|---|---|
| GB/T 37133 | High-voltage connection systems for electric vehicles |
| QC/T 1067.1-2017 | Connectors for automotive wiring harnesses and electrical equipment |
| SAE USCAR-2 / USCAR-38 | Automotive connector performance and ultrasonic welding standards |
| LV 215 / LV 216-2 (ISO 14572) | German OEM high-voltage connector and cable standards |
| GB/T 20234.1/.2/.3 | AC and DC charging interface standards for the charging inlets |
Testing behind these standards — thermal shock, humidity, salt spray, vibration and mechanical endurance — runs in our own environmental and functional labs.
An HV power loom, before it goes into the vehicle
Send the connector code or the routing drawing
We quote HV connectors, PDU units and power looms from your part number, sample or vehicle platform. Engineering answers in English within one business day.