EV Charging Socket Wiring Harness Manufacturer & Supplier
AC Charging Socket Wiring Harness Overview
An EV charging socket wiring harness is the electrical backbone between a vehicle's AC charging inlet and its onboard charging system. It carries both power and communication signals, so its construction directly affects charging safety, installation efficiency, and long-term reliability in the field.
Dongguan Songyuan Technology Co., Ltd. (WireHarnessMaker) manufactures new energy vehicle AC charging socket wiring harness assemblies at our 2,000 sqm factory in Houjie Town, Dongguan. Founded in 2017, we operate four in-house zones — a harness production workshop, a drawing and extrusion workshop, a quality inspection area, and a warehousing and shipping area — supported by a team of 60 employees. Our product range covers electronic wires, new energy storage wires, shielded power cables, ribbon cables, color ribbon cables, and complete wire harnesses for consumer electronics, industrial control, medical, energy storage, new energy, hydrogen energy, and military-grade cable assembly applications.
Each AC charging socket harness is built as a dedicated charging adapter that provides dual protection for signal and power, comprehensive protection for safe and compliant charging, vehicle-grade durability for high-frequency charging, and integrated error prevention for efficient installation and maintenance. We serve customers across Southeast Asia and exhibited at NCH2025, the Shanghai International New Energy Connector and Wire Harness Processing Technology Exhibition.
Key Features
- Dual signal and power protection — a dedicated charging adapter design that safeguards both the power path and the communication path.
- Comprehensive protection — engineered for safe, compliant charging behavior across the full assembly.
- Vehicle-grade durability — built to withstand high-frequency charging cycles over the vehicle's service life.
- Integrated error prevention — connector and terminal design that reduces mis-assembly during production and maintenance.
- Full customization envelope — power, materials, protection level, socket type, layout, marking, and packaging can all be specified per vehicle program.
Specifications
The following reference dimensions reflect the customization options available for this AC charging socket wiring harness assembly.
Vehicle & Socket Compatibility
Compatible with mainstream EV models and matched to GB (China), Type 2 (Europe), or J1772 (US) AC charging sockets. Vehicle model, charging socket installation position (fender or trunk), and socket interface specifications are required to confirm precise compatibility with the vehicle body and socket.
Power & Electrical Specification
- Power: 3.3kW~22kW
- Current: 16A~32A
- High-voltage wire: 1.5mm²~6mm²
- Communication wire: 24~16AWG
For 3-phase AC 380V (22kW), 4mm²~6mm² wires are recommended. For runs longer than 3m, conductor upsizing is required to reduce power loss.
Material & Protection
- Conductor: tinned copper / bare copper / silver-plated copper
- Sheath: TPU / PVC / low-temperature resistant material
- Protection level: IP67~IP68
Low-temperature resistant sheath is recommended for northern regions (below -40°C), anti-corrosion material for coastal high-salt-fog scenarios, and IP68 protection for frequent outdoor charging.
Socket & Terminal Options
Sockets: GB / Type 2 / J1772, in locked or unlocked versions. Terminals: high-voltage crimp / quick-connect / error-proof. Locked sockets suit public transportation scenarios to prevent accidental disconnection; quick-connect terminals suit frequent maintenance; error-proof terminals suit bulk assembly.
Integrated Functions
Charging indicator light, overcurrent protection fuse, and communication filter module can be integrated. The indicator light must match vehicle body voltage; the fuse's rated current should adapt to the charging power (1.25x rated current is recommended); the filter module is compatible with the GB/T 27930 protocol.
Layout & Length
Length: 1m~5m, adapting to vehicle body wiring. Power, communication, and ground wire branches can be integrated as needed. A vehicle body wiring diagram is required; branch positions must avoid moving parts and high-temperature areas such as the engine compartment to ensure proper installation space.
Marking & Compliance
Custom vehicle number, voltage level, charging power, and safety warnings. For bulk orders of 30 sets or more, free laser marking is provided, with labels such as "AC 220V", "Charging Only", and "High Voltage Danger" to meet the vehicle's compliance requirements.
Packaging
Individual moisture-proof packaging per set (standard), bulk anti-static packaging, or export-customized packaging. For export vehicle supporting, IEC-compliant anti-static packaging is optional to prevent damage to sockets or wiring harnesses during transportation.
Certificates available upon request.
Applications
These AC charging socket wiring harness assemblies are used in new energy vehicle charging systems where a reliable, correctly matched connection between the charging inlet and the vehicle's onboard charging circuit is required. Common configurations include:
- Passenger EV AC charging inlets mounted on the fender or in the trunk
- Public transportation and fleet vehicles requiring locked socket designs to prevent accidental disconnection
- Vehicles charged frequently outdoors, where IP67~IP68 protection is specified
- Programs destined for China, Europe, or US markets using GB, Type 2, or J1772 interfaces
- Bulk vehicle assembly lines where error-proof terminals and laser marking support efficient, compliant production
Related assemblies include our new energy vehicle wiring harness range and high-voltage wire and cable assemblies for new energy vehicles.
Customization & Ordering
Every AC charging socket wiring harness we produce is built to the customer's drawing and vehicle program. To quote accurately, please share your vehicle model, socket interface standard, installation position, required power and current, routing length, and a vehicle body wiring diagram where branch layout is involved.
For standard specifications, prototyping is stated at 48 hours. Order quantities are flexible: prototype runs are stated from 100 pcs, and volume production from 1,000 pcs. Mass production typically ships in 15–25 days.
Bulk orders of 30 sets or more include free laser marking.
Request a Quote
Tell us about your charging socket harness project and our engineering team will review your requirements, confirm the correct wire gauge and protection level for your application, and prepare a quotation.
- Email: [email protected]
- Phone / WhatsApp: +86 13632743143
- Address: No. 26 Fumin Road, Houjie Town, Dongguan City
CTA
If your project also covers the high-voltage power side, see our high voltage EV cable assembly.
Request a Quote or Talk to an Engineer today — we will help you specify an EV charging socket wiring harness assembly that fits your vehicle platform, your interface standard, and your production schedule.