Power and battery cable assemblies for EV packs, BESS racks, charging infrastructure, and industrial power distribution. Hydraulic lug crimp, XLPE insulation, and 100% resistance measurement on every unit.
A standard 1A continuity test will pass a cold-crimped lug with 50 milliohms of contact resistance. At 200 amps, that 50 milliohms generates 2 watts of heat at the terminal — enough to degrade the insulation and eventually cause a thermal event. The only way to detect a marginal crimp joint is a resistance measurement with enough resolution to see the difference between a 1 milliohm good crimp and a 50 milliohm marginal crimp.
For applications requiring HV insulation on top of high current, see high-voltage harness — we stack the orange jacket and hipot test with the power cable construction. For waterproof power cables used in marine and outdoor applications, see waterproof harness for the IP sealing method that works with heavy-gauge conductors.
