BNC Male to DC Plug Cable Harness Construction Guide

BNC connectors are used for coaxial cables. They feature a snap-on design for quick connection and disconnection. They consist of a center pin, a jacket, and a base. They come in male (with a pin) and female (with a socket). They are commonly used for radio frequency signal transmission, such as video, audio, and antenna connections. They were once used in 10base2 Ethernet, but have now been superseded by twisted-pair cables.

Prepare materials

Main cable: UL2464 26AWG x 2C

Connector: BNC male (signal transmission) + DC plug (5.5 x 2.1 mm). The BNC male connector is made of high-quality, oxidation-resistant zinc alloy, with a plug-in/plug life of ≥500 cycles and a signal transmission impedance of 75 ohms.

Heat shrink tubing: 300V pressure-resistant heat shrink tubing with a shrinkage rate of ≥50% and an insulation resistance of ≥100MΩ

Injection molding material: The left connector uses a double-layer "inner film + outer mold" injection molding, achieving an IP54 seal (dust and splash resistance). The outer mold is 45P black PVC with a hardness of 90A and a tensile strength of ≥15MPa.

Production process

Wire Cutting and Stripping: Wires are cut to a length of 230mm with an accuracy of ≤±0.5mm using a fully automatic wire cutting machine, resulting in a 99% smooth cut surface. When stripping, 30mm of the outer jacket is stripped off on the right end (to facilitate crimping terminals) and 10mm on the left end (to facilitate soldering). The depth tolerance is ≤0.1mm to avoid damaging the conductor.

Injection Molding: The left-end connector is molded using low-pressure injection molding (5-8 bar). An inner film (low-density PE) is applied for initial sealing, followed by an outer mold (45P PVC) covering the inner film and base. The final diameter is 8-10mm, and the base can withstand a tensile force of ≥30N, enhancing tensile strength.

Heat Shrink Tubing and Sealing: The heat shrink tubing should be 20mm (±1mm tolerance) away from the right end of the plastic shell. After heat shrinking at 120° C, the tubing must fit snugly, free of bubbles and wrinkles. The right end should be sealed with UV adhesive, which cures quickly and provides a strong bond. UV exposure quickly cures and seals the seal. After curing, the insulation resistance should be ≥1000MΩ, and the waterproofing should meet IP64 standards.

Full Testing: Continuity testing is performed using dedicated equipment, requiring a resistance of ≤50mΩ to ensure a clear connection. During the tensile test, a 50N pull is applied to each connector for 30 seconds, with a displacement of ≤1mm. For the airtightness test, a pressure of 50kPa is maintained for 30 seconds, with leakage of ≤0.1kPa/min.

Quality control

Raw material control: Raw materials undergo rigorous inspection before entering storage. Wires must comply with UL2464 standards and pass voltage tests before production. Connectors (such as DC plugs) are tested for material properties and ensure that the brass nickel plating meets specified thickness standards for conductivity and corrosion resistance.

Finished product control: Before shipment, in addition to routine tests such as continuity, tensile strength, and airtightness, samples undergo durability testing. For example, connectors must be plugged and unplugged for at least 5,000 cycles, ensuring that contact resistance changes meet regulatory requirements.

This BNC male to DC plug cable harness, produced by Kaweei's custom wiring harness factory, features meticulous workmanship and comprehensive quality control, ensuring it is stable, durable, and meets customer needs. If you require a custom wiring harness, please contact us.