1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2010 11 29 Revised Added wire size 8 to tables 1 Para 3.1, 3.2, 3.6 , 4 deleted 2001 06 07 Activated R. PatelPrinted copies are uncontrolled Copyright 2010, Ford Global Technologies, Inc. Page 1 of 3 CABLE, PRIMARY LOW TENSION, CROSS LINKED PO
2、LYOLEFIN WSS-M1L123-A5 INSULATED, THIN WALL 1. SCOPE The material defined by this specification is a low tension stranded cable insulated with cross linked polyolefin. The cable is similar to SAE J1128, type TXL. 2. APPLICATION This specification was originally released for S197 and V229 automotive
3、applications requiring the use of cross linked polyolefin insulation. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Stand
4、ard Requirements For Production Materials (WSS-M99P1111-A). 3.3 CONDUCTOR (SAE J1128/ASTM B 1/ASTM B 193) 3.3.1 The conductors shall meet all requirements of SAE J1128 with wire size and stranding as shown in Table 1 of this specification. 3.3.2 Before Bunching The wire must meet the requirements of
5、 ASTM B 1 for tensile strength, elongation, resistivity, dimensions and finish. 3.3.3 Conductor resistance shall be measured by stripping 30 mm of insulation from each end of a 1050 mm cable (use of a longer specimen is optional). Solder (optional) 25 mm along each end of the specimen. Condition the
6、 specimen for a minimum of 4 hours at 23 C +/- 5 C. Measure the unsoldered length, the ambient temperature, and the resistance of the specimen. Calculate the resistance per meter. Calculate the resistance at 20 C using the temperature correction method outlined in ASTM B 193. The maximum resistance
7、values shall conform to those shown in Table 1. ENGINEERING MATERIAL SPECIFICATIONWSS-M1L123-A5 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, Inc. Page 2 of 3 3.4 INSULATION (SAE J1128) 3.4.1 The color of the insulation shall be specified on the engineering drawing of the
8、 component utilizing this material. Base and stripe color shall correspond to SAE J1128. Where striping is specified, the stripe shall be a minimum of 0.3 mm. wide, but not more than 15% of the circumference of the wire. There shall be two same color stripes. The stripes shall be on opposite sides o
9、f the cable. The stripe shall be of the same material as the insulation. If the insulation is died or painted, all the tests must be performed on the finished product. The insulation and the color may show no evidence of peeling or cracking. 3.4.2 The insulating material shall be flame retardant, ho
10、mogeneous, cross-linked polyethylene, similar to SAE J1128 type SXL. The material shall adhere closely to, but strip readily from the conductors, leaving them free of insulation and in suitable condition for applying terminals. Water soluble stripping agents shall not be used. 3.4.3 Insulation thick
11、ness shall comply with the requirements of Table 2. Measure the minimum wall thickness as described in SAE J1128. 3.4.4 There shall be no separators permitted between the core and the insulation. 3.5 CABLE QUALITY (TESTS) (SAE J1128) The finished cable shall meet all performance requirements of SAE
12、J1128 (Revision date 2000-05) type TXL. These tests include strand coating, solderability, mechanical properties, dielectric, cold bend, flame resistance, fluid compatibility, ozone resistance, pinch resistance, sandpaper abrasion resistance, cross-linking, hot water resistance and environmental cyc
13、ling. Below are additional requirements and test modifications: 3.5.1 Insulation Mechanical Properties Test This test shall be conducted in accordance with SAE J1128 for type TXL except that the test temperature shall be 160 +/- 2 C. 3.5.2 All cable shall be spark tested at 2000 Volts at the final c
14、able handling process prior to being packaged for shipment. All spark failures must be removed. 3.5.3 Insulation shrinkage shall be tested by cutting in the middle of a cable section at least 1.0 m (3 ft) in length and immediately checking for exposed core. No core is allowed to extend past the insu
15、lation. Care must be taken to assure the cable is not elongated prior to testing. ENGINEERING MATERIAL SPECIFICATIONWSS-M1L123-A5 Printed copies are uncontrolled Copyright 2010, Ford Global Technologies, Inc. Page 3 of 3 3.5.4 High Temperature Resistance 25 mm of the insulation shall be removed from
16、 each end of a 600 mm sample of the finished cable. The sample shall be suspended around a cylindrical mandrel having a diameter specified in Table 4. The weight specified for the Cold Bend Test above (SAE J1128, Type SXL) shall be suspended from each end of the conductor. This condition shall be ma
17、intained for 168 h in a mechanical convection oven at a temperature of 165 +/- 2 C. When cool, the specimen shall be removed from the mandrel and wrapped in the reverse direction around a mandrel of the diameter specified for the Cold Bend Test in the manner prescribed for the Cold Bend Test. The sp
18、ecimen shall then be subjected to the Dielectric Test (SAE J1128). Note: To ensure insulation material does not adhere to the mandrel during high temperature exposure, the mandrel should be wrapped using a Teflon tape in the areas that will come in contact with the primary wires. Table 1 SAE Wire Si
19、ze Minimum number of Strands Conductor dia. Nom. Size mm (in.) Reference only Minimum Conductor Area mm(cir. mil.) Minimum Strand Size mm (in.) Max. Resistance 20C (mohms/m) Reference only 22 7 0.73 (0.029) 0.325 (641) 0.243 (0.0096) 53.2 20 7 0.92 (0.036) 0.508 (1002) 0.304 (0.0120) 31.5 18 19 1.14
20、 (0.045) 0.762 (1503) 0.226 (0.0089) 22.7 16 19 1.38 (0.054) 1.128 (2226) 0.274 (0.0108) 15.7 14 19 1.77 (0.070) 1.859 (3668) 0.353 (0.0139) 9.29 12 19 2.23 (0.088) 2.928 (5777) 0.443 (0.0174) 5.90 10 19 2.81 (0.111) 4.663 (9200) 0.559 (0.0220) 3.72 8 37 3.52 (0.139) 7.265 (14334) 0.500 (0.0197) 2.3
21、9 Table 2 Finished Cable Diameter mm (in.) SAE Wire Size Minimum Insulation Thickness mm (in.) Nominal Insulation Thickness mm (in.) Maximum Minimum Nominal 22 0.28 (0.011) 0.4 (0.016) 1.63 (0.064) 1.47 (0.058) 1.55 (0.061) 20 0.28 (0.011) 0.4 (0.016) 1.80 (0.071) 1.64 (0.065) 1.72 (0.068) 18 0.28 (
22、0.011) 0.4 (0.016) 2.02 (0.080) 1.86 (0.073) 1.94 (0.076) 16 0.28 (0.011) 0.4 (0.016) 2.25 (0.089) 2.09 (0.082) 2.17 (0.085) 14 0.28 (0.011) 0.4 (0.016) 2.66 (0.105) 2.50 (0.098) 2.58 (0.102) 12 0.32 (0.013) 0.44 (0.017) 3.20 (0.126) 3.04 (0.120) 3.12 (0.123) 10 0.35 (0.014) 0.50 (0.019) 3.88 (0.153) 3.72 (0.146) 3.80 (0.150) 8 0.39 (0.015) 0.55 (0.022) 4.54 (0.179) 4.62 (0182) 4.70 (0.185)
