Customised wiring harnesses for agricultural drones

【Source】: New Product Report: 2.54mm 8-pin Male to Female Customised Harness Cable

【Author】: Hinicable Technical Director: Mrs Bi Yang

【Main Content】:

Firstly, a rough sketch of the external structure was drawn based on the client’s concept, as shown in the figure above, and the specifications and requirements were compiled:

1. Select suitable solid copper pins (male and female ends)
2. Manufacturing process: Soldering method, whereby the wire conductors are soldered to the copper pins
3. The male and female pins require internal frames for fixation, with 8 pins each
4. The insertion depth of the male pin into the female end must be 3.0–3.3 mm
5. After mating the male and female connectors, a silicone waterproof O-ring must be fitted to the female end; once secured, this must achieve an IP68 waterproof rating
6. The female end must be fitted with an M2.5 × 4 mm knurled brass nut, whilst the male end must be secured with an M2.5 × 12 mm cross-head screw
7. Custom cable specification: UL2464 24 AWG × 8-core + AL + PVC jacket cable
8. After mating, the connector supports a working current of DC 24V 3A

Following verification of all materials, specifications and requirements, the process is as follows:

① Injection moulding of male and female internal frames (PBT flame-retardant) — ② Assembly of P-pins — ③ Soldering — ④UV adhesive curing — ⑤ Injection moulding of inner mould — ⑥ Electrical performance testing — ⑦ Injection moulding of outer mould — ⑧ Electrical performance testing — ⑨ Nut assembly — ⑩ Water resistance testing– ⑾ CCD inspection of mating depth — ⑿ Visual inspection — ⑿ Packaging

Through the customisation of this 8-pin cable assembly, we have demonstrated rigorous material selection and process evaluation for this drone propeller power supply cable assembly. We first used a PBT inner frame to fix the pin spacing, ensuring stability and the absence of interference when powered, with smooth operation and no electromagnetic interference. The power supply is divided into four stable groups, Meanwhile, the silicone waterproof O-rings were embedded to ensure a tight seal; when mated with the male connector, the assembly met the IP68 waterproofing standard.

Additionally, the airtightness test met the requirements: under a 24V 3A load for 12 hours, the conductor temperature rise was +0.26°C, complying with electrical load capacity specifications. This new product development fully meets the client’s requirements and has passed the client’s validation tests. It is now ready for mass production.