What Gauge Wire in Our Factory Wiring Harness?
What is Wire Gauge?
A wire gauge is a measurement of wire diameter. This determines the amount of electric current the wire can safely carry, as well as its electrical resistance and weight.
What is AWG?
American Wire Gauge (AWG), also known as the Brown & Sharpe wire gauge, is a standardized wire gauge system used predominantly in North America for the diameters of round, solid, nonferrous, electrically conducting wire. The AWG system is based on a logarithmic stepped set of wire sizes, where the diameter and cross-sectional area of the wire decrease as the gauge number increases. The number in front of the AWG (e.g. 24AWG, 26AWG) indicates the number of holes the wire will pass through before forming the final diameter. The larger the number, the more holes the wire will pass through and the smaller the diameter of the wire.
Chinese Wire Gauge (CWG)
The Chinese Wire Gauge (CWG) is a standardized system in China for defining wire diameters and cross-sectional areas, measured in millimeters (mm) and square millimeters (mm²). It follows GB (Guobiao) standards and is used in electrical wiring and power distribution. CWG sizes differ from AWG or SWG, so direct conversion isn't possible. Common sizes include 1.5 mm², 2.5 mm², and 4 mm², with corresponding diameters like 1.38 mm and 1.78 mm. Always refer to specific GB standards (e.g., GB/T 5023) for accurate specifications.
| Chinese Wire Gauge | American Wire Gauge | Sectional Area | Value of Resistance | Carrying Capacity | |||
| CWG | AWG | Regular | Max | ||||
| wire diameter (mm) | wire size | wire diameter (mm) | wire diameter (inch) | mm² | Ω/km | A | A |
| --- | 4/0* | 11.684 | 0.4600 | 107.2200 | 0.17 | 423.2 | 482.6 |
| --- | 3/0* | 10.404 | 0.4096 | 85.0100 | 0.21 | 335.5 | 382.6 |
| 9.00 | 2/0* | 9.266 | 0.3648 | 67.4300 | 0.26 | 266.2 | 303.5 |
| 8.00 | 1/0* | 8.252 | 0.3249 | 53.4900 | 0.33 | 211.1 | 240.7 |
| 7.10 | 1 | 7.348 | 0.2893 | 42.4100 | 0.42 | 167.4 | 190.9 |
| 6.30 | 2 | 6.543 | 0.2576 | 33.6200 | 0.53 | 132.7 | 151.3 |
| 5.60 | 3 | 5.827 | 0.2294 | 26.6700 | 0.66 | 105.2 | 120.0 |
| 5.00 | 4 | 5.189 | 0.2043 | 21.1500 | 0.84 | 83.5 | 95.2 |
| 4.50 | 5 | 4.620 | 0.1819 | 16.7700 | 1.06 | 66.2 | 75.5 |
| 4.00 | 6 | 4.115 | 0.1620 | 13.3000 | 1.33 | 52.5 | 59.9 |
| 3.55 | 7 | 3.665 | 0.1443 | 10.5500 | 1.68 | 41.6 | 47.5 |
| 3.15 | 8 | 3.264 | 0.1285 | 8.3700 | 2.11 | 33.0 | 37.7 |
| 2.80 | 9 | 2.906 | 0.1144 | 6.6300 | 2.67 | 26.2 | 29.8 |
| 2.50 | 10 | 2.588 | 0.1019 | 5.2600 | 3.36 | 20.8 | 23.7 |
| 2.24 | 11 | 2.304 | 0.0907 | 4.1700 | 4.24 | 16.5 | 18.8 |
| 2.00 | 12 | 2.052 | 0.0808 | 3.3320 | 5.31 | 13.1 | 14.9 |
| 1.80 | 13 | 1.829 | 0.0720 | 2.6270 | 6.69 | 10.4 | 11.8 |
| 1.60 | 14 | 1.628 | 0.0641 | 2.0750 | 8.45 | 8.2 | 9.4 |
| 1.40 | 15 | 1.450 | 0.0571 | 1.6460 | 10.6 | 6.5 | 7.4 |
| 1.25 | 16 | 1.290 | 0.0508 | 1.3180 | 13.5 | 5.2 | 5.9 |
| 1.12 | 17 | 1.151 | 0.0453 | 1.0260 | 16.3 | 4.1 | 4.7 |
| 1.00 | 18 | 1.024 | 0.0403 | 0.8107 | 21.4 | 3.2 | 3.7 |
| 0.90 | 19 | 0.912 | 0.0359 | 0.5667 | 26.9 | 2.6 | 2.9 |
| 0.80 | 20 | 0.813 | 0.0320 | 0.5189 | 33.9 | 2.0 | 2.3 |
| 0.71 | 21 | 0.724 | 0.0285 | 0.4116 | 42.7 | 1.6 | 1.9 |
| 0.63 | 22 | 0.643 | 0.0253 | 0.3247 | 48.5 | 1.280 | 1.460 |
| 0.56 | 23 | 0.574 | 0.0226 | 0.2588 | 54.3 | 1.022 | 1.165 |
| 0.50 | 24 | 0.511 | 0.0201 | 0.2047 | 79.6 | 0.808 | 0.921 |
| 0.45 | 25 | 0.455 | 0.0179 | 0.1624 | 89.4 | 0.641 | 0.731 |
| 0.40 | 26 | 0.404 | 0.0159 | 0.1281 | 128 | 0.506 | 0.577 |
| 0.355 | 27 | 0.361 | 0.0142 | 0.1021 | 143 | 0.403 | 0.460 |
| 0.315 | 28 | 0.320 | 0.0126 | 0.0804 | 227 | 0.318 | 0.362 |
| 0.28 | 29 | 0.287 | 0.0113 | 0.0647 | 289 | 0.255 | 0.291 |
| 0.25 | 30 | 0.254 | 0.0100 | 0.0507 | 321 | 0.200 | 0.228 |
| 0.244 | 31 | 0.226 | 0.0089 | 0.0401 | 367 | 0.158 | 0.181 |
| 0.20 | 32 | 0.203 | 0.0080 | 0.0316 | 583 | 0.128 | 0.146 |
| 0.18 | 33 | 0.180 | 0.0071 | 0.0255 | 944 | 0.101 | 0.115 |
| 0.16 | 34 | 0.160 | 0.0063 | 0.0201 | 956 | 0.079 | 0.091 |
| 0.14 | 35 | 0.142 | 0.0056 | 0.0169 | 1200 | 0.063 | 0.072 |
| 0.125 | 36 | 0.127 | 0.0050 | 0.0127 | 1530 | 0.050 | 0.057 |
| 0.112 | 37 | 0.114 | 0.0045 | 0.0098 | 1377 | 0.041 | 0.046 |
| --- | 38 | 0.102 | 0.004 | 0.0081 | 2400 | 0.032 | 0.036 |
| --- | 39 | 0.089 | 0.0035 | 0.0062 | 2100 | 0.025 | 0.028 |
| --- | 40 | 0.079 | 0.0031 | 0.0049 | 4080 | 0.019 | 0.022 |
| --- | 41 | 0.071 | 0.0028 | 0.004 | 3685 | 0.016 | 0.018 |
| --- | 42 | 0.064 | 0.0025 | 0.0032 | 6300 | 0.013 | 0.014 |
| --- | 43 | 0.056 | 0.0022 | 0.0025 | 5544 | 0.010 | 0.011 |
| --- | 44 | 0.051 | 0.002 | 0.002 | 10200 | 0.008 | 0.009 |
| --- | 45 | 0.046 | 0.0018 | 0.0016 | 9180 | 0.006 | 0.007 |
| --- | 46 | 0.041 | 0.0016 | 0.0013 | 16300 | 0.005 | 0.006 |
Note:
- (*) 4/0 represents 0000, 3/0 represents 000, 2/0 represents 00, and 1/0 represents 0.
- The wire diameters listed in the table refer to the outer diameters of the wires. Unit conversion: 1 inch = 25.4 mm; 1 inch = 1000 mils.
- I (normal) (A) = D (outer diameter)² / 500; I (maximum) (A) = D (outer diameter)² / 438.489.
- The relationship between AWG and inches can be summarized from the table as follows: AWG = -19.93156857 * log (wire diameter in inches) - 9.73724.
How to Select Wire Size in Wiring Harness?
Selecting the correct wire size in a wiring harness ensures safety, efficiency, and performance. Follow these steps:
1. Determine Current Load: Calculate the current (Amps) using I = P/V (Power/Voltage).
2. Check Ampacity: Use the above wire ampacity tables to find a gauge that handles the current without overheating. For example:
- - 18 AWG: 3.2-3.7A
- - 16 AWG: 5.2-5.9A
- - 14 AWG: 8.2-9.4A
3. Calculate Voltage Drop: Ensure voltage drop is within limits (<3% for power circuits). Use:
Voltage Drop = 2 x L x I x R (L = length, I = current, R = resistance per unit length).
4. Consider Environment: Choose insulation (e.g., PVC, Teflon) for temperature, abrasion, or chemical exposure. Use stranded wire for flexibility.
5. Select Gauge: Choose the smallest gauge meeting current, voltage drop, and environmental needs.
6. Verify Standards: Ensure compliance with UL, SAE, or ISO standards.
7. Test: Validate performance under real-world conditions.
Example: A 12V, 100W light draws 8.33A. For 10 feet, 16 AWG may exceed voltage drop limits; use 14 AWG instead.
By following these steps, you can select the right wire size for your wiring harness.
What Gauge Wire in Our Factory Wiring Harness?
Our company is your trusted partner for wire harness solutions, offering expert processing capabilities for wire gauges ranging from 4/0 AWG to 36 AWG. Whether you require heavy-duty wiring for high-power applications or ultra-fine wires for precision electronics, we have the expertise and technology to meet your needs. Our team is dedicated to delivering high-quality, customized wire harnesses tailored to your specifications, ensuring optimal performance and reliability. If your project involves wires within this extensive range, we invite you to send us your wire harness inquiry. Let us provide you with efficient, cost-effective, and industry-leading solutions to power your innovations and applications.
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