Custom EV Wire Harness & Cable Assembly Manufacturer

Yihetai manufactures custom EV wire harnesses for electric vehicle battery systems, BMS sampling circuits, charging interfaces, motor controllers, temperature monitoring, low-voltage control systems, auxiliary equipment, energy storage modules and OEM electric vehicle electronics.

We can customize connector type, wire gauge, cable length, branch structure, circuit function, shielding, waterproof protection, orange cable identification, labels, sleeves, heat shrink, terminal ends and packaging according to your drawing, sample, wiring diagram, BOM list or connector datasheet.

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What Is an EV Wire Harness?

An EV wire harness is a customized wiring assembly used to connect electric vehicle battery packs, BMS systems, charging ports, motor controllers, sensors, low-voltage control units, auxiliary devices and electronic modules.

 For conventional vehicle electronics and low-voltage automotive systems, Yihetai also manufactures custom automotive wire harness assemblies according to drawings, samples and connector specifications.

EV harnesses can include both high-voltage cable assemblies and low-voltage control wiring. High-voltage cable assemblies are commonly used for power transmission and require careful connector, insulation, cable rating and safety identification review. Low-voltage EV harnesses are commonly used for control signals, sensors, BMS sampling, relays, fans, pumps, displays and vehicle electronics.

EV Wire Harness Design Is Different From General Automotive Wiring

EV wire harness design requires more attention to battery layout, voltage level, current load, circuit separation, cable routing, waterproof protection and safety identification. High-voltage power circuits and low-voltage signal circuits must be properly separated and protected to ensure stable and safe operation.

Yihetai manufactures custom EV wire harnesses according to your battery system, BMS sampling requirements, connector specification and installation environment. We focus on accurate wire sequence, reliable terminal crimping, clear labeling and electrical testing to help ensure each EV harness is ready for long-term use.

EV Wire Harness Types We Manufacture

Yihetai can manufacture different EV wire harnesses and cable assemblies according to customer drawings, samples and application requirements.

  • EV Battery Pack Wire Harness
  • BMS Wire Harness
  • EV Charging Port Harness
  • Motor Controller Wire Harness
  • Low Voltage EV Wire Harness
  • High Voltage EV Cable Assembly
  • Temperature Sensor Wire Harness
  • HVIL Interlock Harness
  • Waterproof EV Wire Harness
  • Shielded EV Cable Assembly
  • Auxiliary Equipment Wire Harness
  • Custom EV Wire Harness Assembly

EV High-Voltage vs Low-Voltage Wire Harness

EV wiring systems may include both high-voltage and low-voltage circuits. These two categories should be clearly separated in design, routing, labeling and inspection requirements.

Item EV High-Voltage Cable Assembly EV Low-Voltage Wire Harness
Main Function Power transmission Signal, control and auxiliary wiring
Common Use Battery system, charging system, power modules BMS signals, sensors, controllers, lighting, accessories
Key Requirement Current capacity, insulation, terminal contact, routing protection Pin assignment, wire sequence, connector matching, signal stability
Cable Size Usually larger conductor size Usually smaller wire gauge
Quality Focus Crimping strength, insulation resistance, withstand voltage Continuity, polarity, wire sequence, label accuracy
Typical Components High-voltage cable, power terminals, protective sleeves Connectors, terminals, labels, small-gauge wires

For battery pack power connection and energy storage applications, Yihetai can also provide custom battery cable assemblies with suitable wire gauge, terminal type, insulation and protection options.

Battery Pack & BMS Sampling Harness Design

Battery pack and BMS sampling harnesses require accurate wire sequence, clear channel identification and stable connector assembly. A wrong sampling wire or incorrect connector cavity may cause monitoring errors or installation problems.

Design ItemWhy It Matters
Sampling Channel LabelHelps identify each battery cell or module channel
Wire SequencePrevents wrong voltage sampling connection
Connector Cavity CheckEnsures each wire is inserted into the correct position
Wire Color CodingHelps installation and maintenance
Temperature Sensor WiringSupports battery thermal monitoring
Harness RoutingMust match battery pack layout
Insulation ProtectionReduces risk of wire damage inside battery pack
Electrical TestConfirms continuity and wiring accuracy before shipment
Approved SampleHelps maintain batch consistency
Final Appearance InspectionConfirms label position, routing and assembly quality

Yihetai can customize BMS sampling harnesses with channel labels, connector cavity verification, wire sequence testing and final inspection according to customer drawings or battery pack layout.

Charging Port & Motor Controller Harness Design

EV charging and motor controller harnesses may require reliable connector matching, waterproof protection, shielding, vibration resistance and clear circuit identification. For charging interfaces, outdoor EV equipment and moisture-exposed wiring areas, Yihetai can also manufacture IP67/IP68 waterproof cable assemblies with sealed connector and overmolding options.

EV Application Area Typical Harness Requirements
EV Charging System Waterproof connectors, signal control wiring and charging port connection
Battery Pack System Voltage sampling harnesses, temperature sensing harnesses and power connections
BMS System Cell monitoring, signal transmission and connector accuracy
Motor Control System Shielded cables, vibration resistance and stable electrical connection
High Voltage Distribution High-current cable assemblies, insulation protection and secure terminals
Vehicle Control System Low-voltage signal harnesses, CAN communication and electronic module wiring
Thermal Management System Temperature sensors, cooling fan wiring and pump connections
Auxiliary Equipment Displays, lighting modules, sensors and control accessories

For EV harness projects, please provide the connector datasheet, wiring diagram, voltage, current, cable length and installation environment before quotation.

Cable Protection, Shielding & Labeling Options

EV wire harnesses may be installed inside battery packs, near chassis, around charging ports, close to motor controllers or inside vehicle electronics modules. Different areas require different protection and identification methods.

Option Purpose
Orange HV Cable High-voltage circuit identification
Shielded Cable EMI protection and signal stability
Corrugated Conduit Mechanical protection and routing support
Braided Sleeve Abrasion protection and clean harness appearance
Heat Shrink Tube Insulation, sealing and strain relief
Dual-Wall Heat Shrink Moisture protection and stronger sealing when required
Waterproof Connector Moisture and dust protection
Rubber Boot / Grommet Connector or panel pass-through protection
Cable Label Circuit identification and installation support
Barcode Label Production traceability and batch control
Warning Label Voltage, polarity or safety-related identification
Color Marking Helps identify

Yihetai can customize protection sleeve, labels, heat shrink, conduit and cable marking according to your EV system assembly requirement. For motor controllers, BMS signals and EV electronic modules, Yihetai can also design custom EMI shielded cable assemblies to improve signal stability in high-noise environments.

Connector, Terminal & Cable Structure Options

Connector and terminal selection has a direct impact on EV harness performance, installation and reliability. Yihetai can help review connector model, terminal type, wire gauge and cable structure according to customer drawings or samples.

ComponentAvailable Options
Connector TypeHV connector, sealed connector, signal connector, circular connector or customer-specified connector
Terminal TypeCrimp terminal, ring terminal, power terminal, signal terminal or custom terminal
Cable TypeOrange HV cable, low-voltage cable, shielded cable, multi-core cable or custom cable
End StructureConnector to connector, connector to open end, terminal end, ring lug or mixed connector
Branch Structure1-to-1, Y-branch, multi-branch, sampling harness or custom layout
Sealing MethodWaterproof connector, rubber boot, heat shrink, grommet or overmolding
ProtectionCorrugated conduit, braided sleeve, tape wrapping, heat shrink or label
IdentificationChannel label, circuit label, barcode label, warning label or color marking

Key Features of Our Custom EV Wire Harnesses

  1. Custom EV battery pack harness, BMS sampling harness and charging port harness
  2. High-voltage cable assembly and low-voltage control harness support according to drawings
  3. Orange HV cable identification, shielded cable and waterproof connector options
  4. Custom connector type, terminal type, wire gauge, cable length and branch structure
  5. BMS sampling channel labels, wire sequence control and connector cavity verification
  6. Corrugated conduit, braided sleeve, heat shrink, grommet and rubber boot protection
  7. Custom labels, barcode labels, warning labels and packaging
  8. Suitable for battery systems, BMS, charging systems, motor controllers and EV electronics
  9. Prototype samples and mass production supported

Applications of Our EV Wire Harnesses

Custom EV wire harnesses are widely used in electric vehicle power, battery monitoring, control and auxiliary electronic systems.

EV Battery Packs
Custom harnesses for battery module connection, battery pack wiring and internal battery system routing.

BMS Sampling Systems
Multi-wire sampling harnesses for voltage sampling, temperature sensing and battery monitoring.

Charging Port Systems
Custom EV charging harnesses for charging interface connection, signal wiring and waterproof protection.

Motor Controllers
Wire harnesses for controller connection, signal wiring, shielding and vibration-resistant installation.

Low-Voltage Control Systems
12V / 24V control harnesses for relays, sensors, modules and auxiliary EV electronics.

Temperature Monitoring
Sensor harnesses for battery, motor and control system temperature monitoring.

Energy Storage Modules
Cable assemblies for energy storage battery monitoring, power connection and control systems.

Auxiliary EV Electronics
Custom harnesses for fans, pumps, displays, lights, control boxes and OEM EV devices.

 

Application-Specific EV Harness Design Notes

Different EV systems require different cable structures, connector matching and protection designs. Yihetai can help review your application and recommend a suitable harness solution.

  1. Application
  2. Connector Information
  3. Wire Information
  4. Cable Length
  5. Quantity
  6. Drawing / Sample
  7. Special Requirements

Technical documents may include drawings, wiring diagrams, BOM lists, connector specifications or sample photos.

Ready to Discuss Your EV Harness Project?

Send us your drawing, sample or basic requirements. Our engineering team will review your project and provide a quotation within 24 hours.
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Certified Wire Harness Factory for EV and Automotive Applications

Yihetai is not only a trading company. We are a wire and wire harness manufacturer with in-house production capabilities. Our company was founded in 2001 and integrates research, production and marketing for electronic wires, wire processing and cable assemblies.

Our quality and product certifications include:

  • ISO 9001
  • IATF 16949
  • UL Appliance Wiring Material: E241406
  • UL Flexible Cord: E241405
  • CCC related wire and cable certifications

Manufacturing Capability

Yihetai is a professional custom cable assembly manufacturer and wiring harness factory with integrated production capability for wire processing, terminal crimping, soldering, welding, assembly, bundling, sleeving, testing and final inspection. Our production range covers automotive harnesses, new energy harnesses, energy storage harnesses, photovoltaic harnesses, machinery wire harnesses and other custom wiring solutions.

For EV wire harness projects, we can support engineering samples, prototype builds, pilot production and mass production. Our process includes incoming material inspection, wire cutting, stripping, terminal crimping, connector assembly, heat shrink processing, sleeve installation, branch bundling, labeling, electrical testing, final inspection and packaging.

Why Choose Yihetai

With over 25 years of experience, Yihetai specializes in custom wire harness and cable assembly solutions for automotive, new energy, industrial, medical, home appliance, and electronic applications

Yihetai’s engineering team supports EV wire harness customization, from drawing review and connector matching to sample development for reliable mass production

Yihetai has proven experience in EV and new energy applications, supporting EV wire harnesses, battery harnesses, energy storage harnesses, automotive harnesses, and charging-related cable assemblies

Yihetai offers flexible production for EV wire harness projects, supporting prototypes, engineering validation builds, small batches, and long-term mass production

Yihetai controls wire cutting, stripping, crimping, welding, injection molding, assembly, and testing in-house to ensure stable quality and reliable delivery

As a professional wire harness and cable assembly manufacturer in China, Yihetai helps customers reduce costs while ensuring consistent quality control

Example Custom EV Wire Harness Projects

Every EV wiring project has different voltage level, connector, routing, labeling and testing requirements. Below are typical custom EV harness projects that Yihetai can support according to customer drawings, samples or application requirements.

Case 1: BMS Sampling Harness

Customer Requirement

The customer needed a battery sampling harness with accurate wire sequence, clear channel labels and stable connector assembly for a battery monitoring system.

Yihetai Solution

Yihetai customized the multi-wire harness according to the customer’s wiring diagram and sampling channel definition.

Our support included:

  • Multi-wire BMS sampling harness assembly
  • Custom labels for sampling channels
  • Connector cavity verification
  • Wire sequence checking
  • Continuity testing
  • Final appearance inspection

Result

The harness helped improve installation accuracy and made each sampling channel easier to identify during battery pack assembly.

Case 2: EV Charging Port Harness

Customer Requirement

The customer needed a charging port harness with reliable connector matching, waterproof protection and clear circuit identification.

Yihetai Solution

Yihetai reviewed the connector interface, cable routing and sealing requirements before production.

Our support included:

  • Charging connector matching
  • Custom cable length and branch structure
  • Waterproof protection with heat shrink and sealing design
  • Circuit label and warning label support
  • Pinout and continuity testing
  • Final visual inspection

Result

The harness was suitable for charging port connection and helped improve assembly efficiency in the customer’s EV system.

Case 3: Motor Controller Signal Harness

Customer Requirement

The customer needed a motor controller harness with stable signal transmission and reliable connection under vibration.

Yihetai Solution

Yihetai customized the harness according to the control system layout and connector requirement.

Our support included:

  • Automotive-grade connector selection according to customer specification
  • Secure terminal crimping
  • Shielded cable option when required
  • Bundling and sleeve protection
  • Connector locking and routing review
  • Pinout and continuity testing

Result

The finished harness provided stable connection for motor controller signal wiring and supported reliable assembly in the customer’s equipment.

Need a custom EV wire harness for your application?

Send us your drawing, sample or technical requirements, and our team will provide a customized wire harness or cable assembly solution for your project.

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Custom Wire Harness & Cable Assembly Manufacturer

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