Automotive Wire
Automotive Wires – Foundation of Modern Mobility
Automotive wires are the backbone of vehicle electrical systems, enabling safe and efficient power delivery, signal transmission, and system integration. From EVs to traditional passenger cars, choosing the right wire ensures performance, reliability, and compliance with international safety standards. Depending on application, automotive wires can be classified into high-voltage cables, U.S./Japanese standards (SAE J1128 & JASO D611), and global benchmarks (ISO 6722).
High Voltage Wire – Powering EVs and Energy Systems
High voltage wire handles voltages above 600V and is essential for EVs, battery packs, industrial machinery, solar systems, and ESS. With silicone, XLPE, or ETFE insulation, these cables offer resistance to heat, oil, and abrasion while meeting UL 758 and ISO 6722. Proper selection by voltage class, temperature rating, conductor type, and insulation ensures long-lasting and safe operation in energy-intensive environments.
Global Automotive Standards – SAE J1128, JASO D611 & ISO 6722
SAE J1128 defines GPT, GXL, SXL, and TXL wires widely used in U.S. vehicles, focusing on abrasion resistance, chemical durability, and heat tolerance up to 125°C. JASO D611 sets requirements for AV, AVS, AVSS, and CAVUS wires used in Japanese and Asian vehicles, emphasizing lightweight and space-saving harnesses. ISO 6722 serves as the international benchmark, covering copper-based conductors, multiple insulation types (PVC, XLPE, TPE, ETFE), and temperature classes up to 150°C. It ensures consistent quality and reliability for global OEMs and harness manufacturers.
High Voltage Cable
High voltage wire is a specialized insulated conductor designed to handle voltages above 600V, essential for high-power and energy-intensive environments. It is widely used in EV systems, industrial equipment, battery packs, solar energy infrastructure, and energy storage systems (ESS), where electrical and thermal reliability is critical.
These wires feature heat, oil, and abrasion-resistant insulation such as silicone, XLPE, or ETFE, tailored to system needs. They comply with global standards like UL 758, and ISO 6722, ensuring both electrical safety and mechanical durability.
Selecting the right high voltage wire requires evaluating voltage class, temperature rating, conductor type, and insulation thickness. Trusted by manufacturers, OEMs, and engineers, these cables support safe, efficient, and long-lasting systems across transportation, energy, ESS, and automation sectors.
SAE J1128
SAE J1128 is a U.S. automotive wire standard established by the Society of Automotive Engineers (SAE) for low-voltage electrical systems in passenger cars, trucks, and off-road equipment. It specifies construction, performance, and testing requirements for primary wires in 12V and 24V systems.
The standard includes wire types such as GPT, GXL, SXL, and TXL, which vary in insulation thickness and temperature ratings. These wires are widely applied in control circuits, lighting, dashboards, engine compartments, and power distribution throughout vehicles.
Designed for demanding automotive environments, J1128-compliant wires provide abrasion, chemical, and heat resistance with flexibility across operating ranges from -40°C to +125°C. Trusted by OEMs and harness manufacturers worldwide, SAE J1128 ensures reliable, safe, and durable vehicle electrical systems.
JASO D611
JASO D611 is a Japanese automotive standard established by the Society of Automotive Engineers of Japan (JASO). It defines construction, performance, and testing requirements for low-voltage automotive wires, mainly used in 12V and 24V systems. The standard ensures stable and safe operation of electrical wiring in demanding vehicle environments.
The specification covers single-core wires applied in engine compartments, chassis wiring, interior electronics, and lighting systems. It evaluates insulation thickness, conductor resistance, heat resistance, cold flexibility, and chemical durability to guarantee reliability against temperature variations, mechanical stress, and exposure to fluids.
Under JASO D611, common wire types include AV, AVS, AVSS, and CAVUS, which differ in insulation wall thickness and current capacity. These wires are widely adopted by Japanese OEMs and Asian automakers, often referenced alongside ISO 6722 and SAE J1128 as global benchmarks for modern automotive wire harness design.
ISO 6722
ISO 6722 is an international standard developed by the International Organization for Standardization (ISO) that defines requirements for single-core low-voltage cables in automotive electrical systems, mainly for 12V and 24V vehicles. It provides global benchmarks for safety, durability, and performance.
The standard covers copper or tinned copper conductors rated up to 60V DC, with temperature classes from -40°C to +150°C. It allows various insulation materials such as PVC, XLPE, TPE, and ETFE to suit different automotive applications.
ISO 6722 specifies key criteria for wire construction, insulation quality, and electrical reliability, including resistance to heat, abrasion, and aging. Widely adopted by OEMs and harness manufacturers, it underpins common wire types like FLRY, AVSS, and TXL, ensuring dependable use in engine compartments, vehicle bodies, and interior electronics.