Custom Battery Cable Assemblies

Y.C. Cable manufactures custom battery cable assemblies for OEM equipment, industrial machinery, transportation systems, power equipment, backup power systems, and other battery-powered applications.

Assemblies are manufactured according to customer-approved drawings, bills of materials (BOM), conductor specifications, terminals, connectors, cable lengths, electrical requirements, environmental requirements, and testing criteria.

Because battery systems can vary significantly in voltage, current, installation, and operating environment, each cable assembly should be manufactured around the specific requirements of the finished equipment.

 

 

Custom Battery Cable Configurations

Battery cable projects may include:

• Battery-to-equipment connections
• Battery-to-power-distribution connections
• Positive and negative battery cables
• Ground and return cables
• Battery interconnect cables
• Terminal-ended battery cables
• Connector-based battery cables
• Multi-conductor battery connections
• Battery power leads
• Equipment power cables
• Customer-specific battery wiring

For broader equipment power connections, visit Power Cable Assemblies.

Electrical Requirements

Battery cable construction should be defined around the electrical requirements of the finished system.

Important project information may include:

• System voltage
• Current requirement
• Conductor size
• Conductor material
• Number of conductors
• Insulation requirements
• Cable length
• Voltage-drop requirements when specified
• Grounding requirements
• Connector or terminal requirements
• Electrical testing criteria

The appropriate conductor size should be determined from the approved electrical, thermal, mechanical, and application requirements rather than a general current rule.

Battery Terminals & Connectors

Depending on the customer-approved design, battery cable assemblies may use:

• Ring terminals
• Cable lugs
• Battery terminals
• Crimp terminals
• Stud connections
• High-current connector systems
• Power connectors
• Customer-specified connectors
• Boots and terminal covers

Exact manufacturer and part-number information should be provided whenever a connector or terminal is already specified.

Cable Length, Routing & Mechanical Requirements

Battery cables should also be reviewed around the physical installation.

Important considerations may include:

• Cable length and tolerance
• Routing path
• Bend radius
• Connector orientation
• Terminal orientation
• Installation space
• Mechanical retention
• Vibration
• Cable movement
• Strain relief
• Service access

Providing installation or routing information can help identify potential manufacturing or fit concerns before production.

Protection & Environmental Requirements

Depending on the equipment environment, battery cable assemblies may require:

• Heat-shrink protection
• Protective sleeving
• Conduit
• Boots
• Terminal covers
• Abrasion protection
• Strain relief
• Labels and polarity identification

Project documentation should also identify requirements involving:

• Temperature
• Moisture
• Dust
• Oil
• Chemicals
• Vibration
• Abrasion
• Outdoor exposure

The selected materials and protection should follow the actual operating requirements of the product.

Battery Cable Applications

Custom battery cable assemblies may support:

• Industrial machinery
• Agricultural equipment
• Transportation equipment
• Automotive systems
• Battery-powered equipment
• Backup power systems
• Power distribution systems
• Material-handling equipment
• Electronic equipment
• Other OEM battery systems

For vehicle-related cable requirements, visit Automotive Cable Assemblies.

For machinery and industrial equipment, visit Industrial Cable Assemblies.

Prototype to Production

Battery cable programs may begin with:

• Engineering prototypes
• NPI builds
• First articles
• Equipment fit evaluation
• Electrical evaluation
• Low-volume production
• Repeat manufacturing

For development-stage builds, visit Quick-Turn Cable Assembly Prototyping.

For released designs with approved drawings and BOMs, visit Build-to-Print Cable Assembly Services.

Battery Cable Manufacturing & Testing

Depending on the approved design, manufacturing may include:

• Cable cutting
• Insulation stripping
• Terminal preparation
• Crimping
• Lug installation
• Connector assembly
• Heat-shrink application
• Protective sleeving
• Labeling and polarity identification
• Electrical continuity testing
• Dimensional inspection
• Visual inspection
• Pull-force or other customer-defined testing when specified

Learn more about Cable Assembly Manufacturing Capabilities.

What We Need to Quote a Battery Cable

Please provide:

• Drawing
• Bill of Materials
• System voltage and current requirements
• Conductor specification
• Cable length and tolerances
• Terminal and connector part numbers
• Terminal orientation
• Environmental requirements
• Prototype or production quantity
• Estimated annual volume
• Inspection requirements
• Electrical testing requirements
• Current revision
• Target delivery date

Frequently Asked Questions

Can Y.C. Cable manufacture custom battery cables from our drawing?

Yes. Battery cable projects can be reviewed using customer drawings, BOMs, conductor specifications, terminals, connectors, dimensions, quantities, and testing requirements.

How is conductor size selected for a battery cable?

Conductor size should be determined from the electrical, thermal, routing, environmental, regulatory, and application requirements of the finished system.

Can battery cable assemblies include boots and heat-shrink?

Yes. Protective boots, heat-shrink, sleeving, labels, and other protection can be included according to the approved design.

Can you support prototype battery cables?

Yes. Prototype and first-article quantities can be reviewed before repeat manufacturing.

Request a Custom Battery Cable Quote

Send us your drawing, BOM, electrical requirements, conductor specification, terminals, quantity, and testing requirements.

Request a Battery Cable Quote