Cable Assembly
Power cable assembly is a family, not a single part. We build custom battery, high-voltage EV, motor/VFD and TC-ER certified power cables with correct conductor sizing and ampacity, lug and crimp termination, and HiPot testing — with each type detailed on its own page so you can go straight to the one your voltage and environment need.
Application Context
Real customer engagements, anonymized to industry and region — no client names are published. The numbers are from the actual programs.
Smart-energy OEM · United States — TC-ER 2AWG power cable engineered. A 2AWG 3-conductor cable had diameter and flexibility constraints, and an initial material substitution for the inner jacket was rejected because it did not meet the mandatory TYPE TC-ER certification required on both inner and outer jackets. We engineered a compliant construction rather than ship a lower-rated substitute. Read the full case study →
Energy-storage SME — 100 custom 2-pin battery assemblies in 12 days. A battery program needed 100 custom 2-pin power assemblies on a compressed timeline. With the release confirmed, the batch was built and shipped inside a 12-day window. Read the full case study →
Both show the same discipline: on power work, conductor rating and jacket compliance are met to the approved spec — not substituted to hit a number. See more wire harness case studies.
Power Assembly Types
Each power family has its own dedicated page with conductor, connector, and test detail — start with the one that fits your voltage and environment.
Battery and energy-storage power cables with heavy-gauge conductors, lug and stud termination, polarity control, and HiPot testing for pack, BMS, and DC distribution.
Orange-jacket EV high-voltage assemblies for battery, traction inverter, BESS and DC fast-charge, with shielding, HV connectors, and dielectric-withstand testing.
Servo motor power, brake, and VFD drive cables with shielding for EMC, connector sourcing, and continuity plus insulation testing for motion-control programs.
TC-ER rated power cable assemblies engineered to the approved jacket and temperature class, for tray-cable and exposed-run installations without substituting a lower-rated material.
Engineering Challenges
Gauge is confirmed against current, distance, temperature, bundle count, and de-rating so the assembly meets its ampacity and voltage-drop targets — not sized by assumption.
TC-ER, UL styles, and temperature class are built to the approved specification. We engineer a compliant construction rather than substitute a lower-rated material to hit a price.
For EV, battery, and HV programs, HiPot at the specified test voltage plus insulation resistance are release gates, with shielding and HV connector handling to the design.
Lug, stud, and crimp terminations on heavy-gauge power are pull-tested and inspected because a poor power termination is a thermal and safety risk, not just a cosmetic one.
Technical Capabilities
Manufacturing Process
Quality & Testing
Power assemblies receive continuity and the agreed dielectric checks — HiPot at the specified voltage and insulation resistance — plus lug/crimp pull-force and polarity verification, documented so engineering and supplier quality work from the same evidence at release.
Why WHP
Power work fails dangerously — an undersized conductor or a non-compliant jacket is a thermal and safety risk, not a cosmetic one.
Gauge, ampacity, and jacket rating are confirmed against the requirement; we engineer a compliant construction rather than substitute a lower-rated material to hit a number.
For EV, battery, and HV programs, dielectric-withstand and insulation testing are standard gates, so an assembly is not released against an untested assumption.
Battery, HV, motor, and TC-ER each have a dedicated page and a distinct build; we point you to the correct one for your voltage and environment.
Lug, stud, and crimp terminations on heavy-gauge power are pull-tested and inspected, because a poor power connection becomes a heat and safety problem in service.
Power cable assembly still needs shared quality language, so buyers can align RFQ wording with IPC/WHMA-A-620 workmanship, UL-758 wire context, and documented ISO 9001-style controls before supplier comparison.
FAQ
OEM Program Entry
Send the drawing, conductor and connector specs, voltage/current, rating (TC-ER/UL), test requirements, and quantity. We will return conductor sizing, lug sourcing, a test plan, and a quote — or point you to the right power assembly family.
Related Capabilities
Go straight to the dedicated page for your power assembly type.
TL;DR
Power cable assembly is a family: battery, high-voltage, motor/VFD, and TC-ER — each with its own page.
Conductor gauge and ampacity are confirmed against current, distance, temperature, and de-rating.
HiPot and insulation testing are release gates for EV, battery, and HV programs.
Jacket and rating (TC-ER/UL) are built to the approved spec — never substituted to hit a price.
Applications
From EV high-voltage to tray-cable TC-ER — matched to the voltage, current, and rating your application needs.
High-voltage battery, traction and BESS power cables with shielding, HV connectors and HiPot release gates.
Servo motor, brake and VFD power cables with EMC shielding for robotics and automation programs.
Battery, inverter and distribution power cables with heavy-gauge conductors and lug/stud termination.
TC-ER rated power cable assemblies for installations that require a tray-cable and exposed-run construction.
Power connectorized assemblies (Anderson, high-current circular) with polarity and current-rating control.
Assemblies where ampacity, voltage drop and termination heat matter — sized and pull-tested to the design.
RFQ Package
Standards
Power cable assembly still needs shared quality language. Public references help buyers align RFQ wording with IPC/WHMA-A-620 workmanship expectations, UL wire and jacket context, and documented ISO 9001-style controls before supplier comparison.
Background for the association behind cable and wire harness workmanship standards used in supplier-quality discussions.
Reference context for buyers reviewing wire, insulation, jacket rating, and component safety language in a power cable RFQ.
Reference context for documented quality-management systems and repeatable release records.
Reviewed by
Founder & General Manager, WellPCB