35mm² High Current Copper Terminal for Off-Road Vehicle Wiring Harness
The KL1888502-180C High Current Copper Terminal is a custom-designed crimp terminal developed for off-road vehicle wiring harnesses and other high-current automotive electrical systems. Manufactured from T2 copper with a high-quality tin-plated finish, it delivers excellent electrical conductivity, corrosion resistance, and long-term mechanical reliability.
Designed for 35mm² cables, this terminal supports currents of 120A and above, making it an ideal solution for off-road vehicles, heavy-duty equipment, electric utility vehicles, agricultural machinery, and other demanding applications.
Customer Requirements
Qianwei Precision Solution
The customer required a custom terminal capable of supporting 35mm² cables with excellent electrical and mechanical performance.
Key requirements included:
- Rated current above 120A
- Rated voltage up to 600V
- High conductivity using pure copper
- Excellent corrosion resistance
- Compatible with automated crimping equipment
- Stable crimping performance
- Tight dimensional tolerances
- Compliance with GB/T 10125-2012 salt spray requirements
- RoHS compliant materials
Qianwei Precision developed a fully customized copper terminal solution based on the customer's application.
Our engineering team optimized the design through:
- Precision U-type crimp barrel for 35mm² cables
- High-conductivity T2 copper material
- Tin plating with minimum 5μm thickness
- Precision progressive stamping technology
- Tight dimensional control for automated assembly
- Optimized crimp ribs to improve pull-out performance
- Surface finishing without burrs, cracks, or oxidation
The result is a reliable high-current terminal capable of maintaining low resistance and stable performance under demanding automotive operating conditions.
Performance Advantages
Superior Electrical Performance
Manufactured from 100% IACS T2 copper, the terminal provides outstanding electrical conductivity with low contact resistance, minimizing voltage drop and power loss during high-current transmission. Designed for 35mm² cables and rated for 120A or above, it ensures stable and efficient power delivery in demanding automotive electrical systems.
Reliable Durability in Harsh Environments
Featuring a minimum 5μm tin-plated surface, the terminal offers excellent resistance to oxidation and corrosion, extending its service life in harsh off-road environments. Its optimized crimp structure and robust mechanical design maintain secure wire retention and reliable electrical connections under continuous vibration, shock, and mechanical stress.
Optimized for Efficient Manufacturing
The precision-engineered U-shaped crimp barrel is designed for high-speed automated crimping, delivering consistent crimp quality and improving production efficiency. Combined with Qianwei's precision stamping technology, the terminal ensures excellent dimensional accuracy and stable performance throughout mass production.
Materials & Manufacturing
Materials
- Copper alloys (high conductivity)
- Optional plating: Tin / Nickel / Gold
Manufacturing Capabilities
- Precision high-speed stamping
- 1800+ mass production tooling sets
- Custom mold development & rapid modification
- Injection molding support (housing integration if required)
Process Control
- Tight tolerance management
- Automated inspection during production
- Stable large-volume output
Parameter | Specification |
|---|---|
| Product Model | KL1888502-180C |
| Product Type | High Current Crimp Terminal |
| Cable Size | 35mm² |
| Material | T2 Copper |
| Surface Finish | Tin Plated |
| Plating Thickness | ≥5μm |
| Rated Current | ≥120A |
| Rated Voltage | 600V |
| Working Temperature | -40°C to +105°C |
| Contact Resistance | ≤0.5mΩ |
| Pull-Out Force | ≥150N |
| Length | 28.4 ±0.5 mm |
| Thickness | 1.80 ±0.05 mm |
| Width | 24.5 ±0.3 mm |
| Height | 9.3 ±0.3 mm |
Testing & Certification
Every production batch undergoes comprehensive quality inspection before shipment.
Testing Items
Salt Spray Test
Passed 96-hour salt spray testing according to GB/T 10125-2012, achieving Appearance Grade 4 or above.
Dimensional Inspection
100% inspection of critical dimensions to ensure compliance with engineering drawings.
Plating Thickness Inspection
Tin plating thickness verified at ≥5μm.
Crimp Performance Test
Verified compatibility with 35mm² cable crimping, ensuring secure mechanical retention.
Electrical Performance Test
Contact resistance remains within industry requirements, providing stable high-current transmission.
Environmental Compliance
Materials comply with RoHS environmental standards.
Results & Customer Feedback
After product development, tooling, sampling, and testing, the KL1888502-180C terminal successfully entered mass production.
Project Results
- Successfully completed custom tooling development
- Passed all customer validation tests
- Achieved stable mass production
- Excellent production yield
- Consistent quality across large production volumes
Customer Feedback
The customer reported:
- Stable crimping performance
- Excellent conductivity
- Smooth compatibility with automated crimping equipment
- High production efficiency
- Reliable quality during long-term production
As a result, the project has developed into a long-term supply partnership.
Why Choose Qianwei Precision?
Precision Stamping Expertise
Over 10 years of experience in precision metal stamping for automotive and industrial electrical terminals.
Custom Terminal Development
We develop customized terminal solutions according to customer drawings, samples, or application requirements.
OEM & ODM Services
From prototype development to high-volume manufacturing, Qianwei provides flexible OEM and ODM support for global customers.
Advanced Mold Design Capabilities
Our in-house tooling department enables rapid mold development, high dimensional accuracy, and stable mass production.
Comprehensive Testing Services
Dimensional Inspection
Ensures every critical dimension meets engineering specifications.
Pull-Out Force Testing
Verifies mechanical retention and crimp reliability.
Vibration Testing
Evaluates terminal stability under continuous vehicle vibration.
Thermal Cycling Testing
Confirms reliable electrical performance across repeated temperature changes.
Contact us today to request samples, technical support, or a customized quotation..
Products
FAQ
Qianwei Precision supplies precision terminals and connectors for trucks, buses, construction machinery, agricultural vehicles, and off-road equipment, including power distribution, control systems, and onboard electronics.
Our products are designed with robust contact structures and secure retention mechanisms, ensuring reliable electrical connections under constant vibration and mechanical shock common in truck and off-road environments.
Qianwei Precision manufactures under IATF 16949 and ISO 9001 quality management systems, and products comply with RoHS and REACH requirements.
Absolutely. We offer custom design and manufacturing services to meet specific vehicle platform requirements, including current rating, packaging constraints, and installation methods.
Yes. Our components are suitable for electric and hybrid commercial vehicles, supporting battery systems, power electronics, and charging interfaces.
Contact
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