SAE J 1128-2015 Low Voltage Primary Cable.pdf

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1、 _ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising ther

2、efrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2015 SAE International All rights reserved. No part of this

3、publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-49

4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J1128_201512 SURFACE VEHICLE STANDARD J1128 DEC2015 Issued 1975-11 Revised 2015-

5、12 Superseding J1128 OCT2013 Low Voltage Primary Cable RATIONALE This standard is being revised to strengthen requirements for low voltage primary cable. TABLE OF CONTENTS 1. SCOPE 2 2. REFERENCES 3 2.1 Applicable Documents 3 2.2 Related Publications . 4 3. DEFINITIONS . 5 4. GENERAL . 7 4.1 Cable T

6、ypes 7 4.2 General Test Conditions . 7 4.3 Ovens 7 4.4 Tolerances 7 4.5 Representative Conductor Sizes for Testing 7 5. GENERAL SPECIFICATIONS 7 5.1 Conductors 8 5.2 Insulation . 9 5.3 Outside Cable Diameter 9 5.4 Wall Thickness 9 5.5 Winding . 9 6. TESTS . 11 6.1 Strand Coating 11 6.2 Solderability

7、 . 11 6.3 Mechanical Properties. 11 6.4 Dielectric . 11 6.5 Insulation Faults 12 6.6 Cold Bend . 12 6.7 Resistance to Flame Propagation . 12 SAE INTERNATIONAL J1128 DEC2015 Page 2 of 24 6.8 Fluid Compatibility . 13 6.9 Resistance to Ozone . 13 6.10 Resistance to Pinch 13 6.11 Resistance to Sandpaper

8、 Abrasion 15 6.12 Crosslinking . 17 6.13 Strip Force . 17 6.14 Resistance to Hot Water . 17 6.15 Insulation Volume Resistivity 18 6.16 Temperature and Humidity Cycling . 19 7. REFERENCE INFORMATION 19 7.1 Color Code 19 8. NOTES 20 8.1 Revision Indicator 20 APPENDIX A FOR INFORMATION ONLY CONDUCTOR A

9、REA METRIC UNITS . 21 APPENDIX B RECOMMENDED COLORS . 22 APPENDIX C SOURCES FOR SAE REFERENCE MATERIALS . 23 FIGURE 1 CABLE TYPES 7 FIGURE 2 GENERAL SPECIFICATIONS 8 FIGURE 3 CONDUCTORS 9 FIGURE 4 “OUTSIDE CABLE DIAMETER” AND “WALL THICKNESS” 10 FIGURE 5 WINDING TEST CONDITIONS 10 FIGURE 6 “MECHANIC

10、AL PROPERTIES” AND “TEMPERATURE AND HUMIDITY CYCLING”, TEST CONDITIONS . 11 FIGURE 7 APPARATUS FOR “FLAME RESISTANCE” TEST 12 FIGURE 8 FLUID COMPATIBILITY . 13 FIGURE 9 APPARATUS FOR “RESISTANCE TO PINCH” TEST . 14 FIGURE 10 MINIMUM “RESISTANCE TO PINCH” . 14 FIGURE 11 APPARATUS FOR “RESISTANCE TO S

11、ANDPAPER ABRASION” TEST 15 FIGURE 12 “RESISTANCE TO SANDPAPER ABRASION”, ADDITIONAL MASS . 16 FIGURE 13 “RESISTANCE TO SANDPAPER ABRASION” 16 FIGURE 14 APPARATUS FOR “RESISTANCE TO HOT WATER” TEST 18 FIGURE 15 PROCEDURE FOR “TEMPERATURE AND HUMIDITY CYCLING” TEST . 19 FIGURE A1 CONDUCTOR AREA (METRI

12、C UNITS) . 21 FIGURE A2 “OUTSIDE CABLE DIAMETER” AND “WALL THICKNESS” (ENGLISH UNITS) . 21 FIGURE B1 RECOMMENDED COLORS REFERENCE SAE EA-1128, WIRE COLOR CHARTS . 22 FIGURE C1 SOURCES FOR SAE REFERENCE MATERIALS . 24 1. SCOPE This standard covers low voltage primary cable intended for use at a nomin

13、al system voltage of 60 V DC (25 V AC) or less in surface vehicle electrical systems. The tests are intended to qualify cables for normal applications with limited exposure to fluids and physical abuse. SAE INTERNATIONAL J1128 DEC2015 Page 3 of 24 2. REFERENCES 2.1 Applicable Documents The following

14、 publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and

15、Canada) or +1 724-776-4970 (outside USA), www.sae.org. SAE EA-1128 Wire Color Charts SAE J311 Fluid for Passenger Car Type Automatic Transmissions SAE R-257 Dictionary of Materials and Testing 2.1.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Consh

16、ohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org ASTM B 33 Standard Specification for Tinned Soft or Annealed Copper Wire ASTM B 263 Method for Determination of Cross-Sectional Area of Standard Conductors ASTM B 298 Standard Specification for Silver - Coated Soft or Annealed Copper Wire ASTM

17、B 354 Definitions of Terms Relating to Uninsulated Metallic Electrical Conductors ASTM B 355 Standard Specification for Nickel-Coated Soft or Annealed Copper Wire ASTM D 412 Standard Test Methods for Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic Elastomers - Tension ASTM D 471 Standa

18、rd Test Method for Rubber Property - Effect of Liquids ASTM D 573 Standard Test Method for Rubber - Deterioration in an Air Oven ASTM D 833 Standard Terminology Relating to Plastics ASTM D 5374 Standard Test Methods for Forced-Convection Laboratory Ovens for Evaluation of Electrical Insulation ASTM

19、D 5423 Standard Specification for Forced-Convection Laboratory Ovens for Evaluation of Electrical Insulation 2.1.3 IEC Publications Available from IEC Central Office, 3, rue de Varembe, P.O. Box 131, CH-1211 Geneva 20, Switzerland, Tel: +41 22 919 02 11, www.iec.ch. IEC 60811-2-1 Common test methods

20、 for insulating and sheathing materials of electrical cables - Part 2: Methods specific to elastomeric compounds - Section 1: Ozone resistance test - Hot set test - Mineral oil immersion test IEC, Electricity, Electronics and Telecommunications, Multilingual Dictionary SAE INTERNATIONAL J1128 DEC201

21、5 Page 4 of 24 2.2 Related Publications The following publications are provided for information purposes only and are not a required part of this SAE Technical Report. 2.2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (insid

22、e USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. SAE J156 Fusible Links SAE J1127 Low Voltage Battery Cable SAE J1654 High Voltage Primary Cable SAE J1673 High Voltage Automotive Wiring Assembly Design SAE J1678 Low Voltage Ultra Thin Wall Primary Cable SAE J2183 60 V and 600 V Singl

23、e - Core Cables SAE J2501 Round, Screened and Unscreened, 60 V and 600 V Multi-Core Sheathed Cables SAE J2840 High Voltage Shielded and Jacketed Cable 2.2.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585,

24、 www.astm.org ASTM B 1 Standard Specification for Hard - Drawn Copper Wire ASTM B 3 Standard Specification for Soft or Annealed Copper Wire ASTM B 8 Concentric - Lay-Stranded Copper Conductors, Hard, Medium - Hard, or Soft ASTM B 452 Standard Specification for Copper-Clad Steel Wire for Electronic A

25、pplication ASTM B 787 19 Wire Combination Unilay-Stranded Copper Conductors for Subsequent Insulation 2.2.3 ISO Publications Available from ANSI, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org. ISO 6722 Road vehicles - 60 V and 600 V single core cables - Test methods,

26、dimensions and requirements ISO 14572 Road vehicles - Round, screened and unscreened, 60 V and 600 V multicore sheathed cables - Basic and high performance test methods and requirements SAE INTERNATIONAL J1128 DEC2015 Page 5 of 24 3. DEFINITIONS 3.1 ADDITIONAL MASS (Reference “Resistance to Sandpape

27、r Abrasion” Test) The mass which is applied to the support rod. The combination of the forces exerted by the additional mass and the 0.63 N exerted by the remaining apparatus (bracket, support rod, and pivoting arm) is applied to the cable. 3.2 CABLE See primary cable. 3.3 CABLE FAMILY A group with

28、multiple conductor sizes having the same conductor strand coating, insulation formulation, and wall thickness type. 3.4 COATED WIRE Wire comprised of a given metal covered with a relatively thin application of a different metal. (ASTM B 354) 3.5 CONDUCTOR A wire or combination of wires not insulated

29、 from one another, suitable for carrying an electrical current. (ASTM B 354) 3.6 CONDUCTOR SIZE See “SAE Conductor Size”. 3.7 CORE One of the components in an assembly. A component may be an uninsulated conductor, an insulated conductor, a twisted pair, a shielded assembly, a coaxial cable, or any f

30、inished cable. 3.8 FLUID COMPATIBILITY The ability of a cable to resist the effects of various fluids found in surface vehicles. 3.9 HOT PLATE An electrically heated device used to test thermoset cables. 3.10 LOW VOLTAGE (LOW TENSION) Usually considered to be d 60 V DC (25 V AC). 3.11 MINIMUM WALL (

31、THICKNESS) The lowest allowable insulation thickness at any point. 3.12 NOMINAL A suitable approximate value used to designate or identify a component. 3.13 PLASTICS A material that contains as an essential ingredient one or more organic polymeric substances of large molecular weight, is solid in it

32、s finished state, and, at some stage in its manufacture or processing into finished articles, can be shaped by flow. (ASTM D 833) SAE INTERNATIONAL J1128 DEC2015 Page 6 of 24 3.14 PRIMARY CABLE The single or multi-stranded, single conductor, insulated cable used to carry electric current, by attachm

33、ent to the low voltage side of an ignition coil in surface vehicles. 3.15 RESISTANCE TO OZONE The ability of a material to withstand the deteriorating effect of ozone (surface cracking). (Dictionary of Materials and Testing) 3.16 SAE CONDUCTOR SIZE A system that indicates the cross sectional area of

34、 the conductor. The Metric SAE Conductor Size is the approximate area of the conductor. 3.17 SEPARATOR A thin layer used as a barrier to prevent mutually detrimental effects between different components of a cable such as between the conductor and insulation or between the insulation and the sheath.

35、 (IEC, Electricity, Electronics and Telecommunications, Multilingual Dictionary) 3.18 STRIP FORCE The peak axial force required to overcome the adhesion between the conductor and the insulation. 3.19 STRAND See wire. 3.20 TCR, TEMPERATURE CLASS RATING A class designation based on the retention of “M

36、echanical Properties” (tensile however, in case of dispute, the referee shall be the optical device. A minimum of two readings shall be taken at each cross section. The sample should be rotated 90 degree between readings. The mean of the diameter readings shall determine the ”Outside Cable Diameter”

37、 and shall be in accordance with Figure 4 Outside Cable Diameter and Wall Thickness for the various cable types. 5.4 Wall Thickness The minimum “Wall Thickness” shall be measured at five separate cross sections spaced 400 mm apart using the equipment described in 5.3 Outside Cable Diameter. No singl

38、e value shall be less than the appropriate “Wall Thickness, Minimum” specified in Figure 4 Outside Cable Diameter and Wall Thickness. 5.5 Winding “Winding” is not a separate test. It is included as a part of several other tests. When it is required, wind the test sample around the mandrel using the

39、“Mandrel Size”, “Winding Speed”, and “Number of Turns, Minimum” shown in Figure 5. Either a revolving or stationary mandrel may be used. Care shall be taken to ensure that there is continuous contact between the test sample and the mandrel. SAE INTERNATIONAL J1128 DEC2015 Page 10 of 24 SAE Cable Typ

40、e SAE TWP TXL GPT GXL SXL HDT HTS Conductor Size Wall Thickness Maximum Outside Cable Diameter Wall Thickness Maximum Outside Cable Diameter Wall Thickness Maximum Outside Cable Diameter Wall Thickness Maximum Outside Cable Diameter No. Nominal mm Minimum mm mm Nominal mm Minimum mm mm Nominal mm Mi

41、nimum mm mm Nominal mm Minimum mm mm 24 0.40 0.28 1.50 - - - - - - - - - 22 0.40 0.28 1.70 - - - - - - - - - 20 0.40 0.28 1.90 0.58 0.41 2.40 0.74 0.52 2.80 0.91 0.64 3.10 18 0.40 0.28 2.20 0.58 0.41 2.50 0.76 0.53 3.00 0.94 0.66 3.40 16 0.40 0.28 2.40 0.58 0.41 2.90 0.81 0.57 3.40 1.02 0.71 3.70 14

42、 0.40 0.28 2.70 0.58 0.41 3.20 0.89 0.62 3.90 1.04 0.73 4.20 12 0.46 0.32 3.30 0.66 0.46 3.80 0.94 0.66 4.60 1.17 0.82 5.10 10 0.50 0.35 4.00 0.79 0.55 4.70 1.04 0.73 5.30 1.17 0.82 5.70 8 0.55 0.39 4.90 0.94 0.66 6.00 1.09 0.76 6.20 1.40 0.98 7.00 NOTE: For reference only, English units are include

43、d in Appendix A. Figure 4 - “Outside cable diameter” and “wall thickness” SAE Conductor Size a Mandrel Size Winding Speed s-1Number of Turns Minimum Reference Clause 6.16 Temperature and Humidity Cycling Reference Clauses 6.6 Cold bend, 68 Fluid Compatibility, 6.9 Resistance to Ozone, however, in ca

44、se of a dispute, the referee method will be a 50 mm/min strain rate. The original and conditioned samples must both be elongated at the same strain rate. The original properties shall conform to the values shown in Figure 6 Mechanical Properties and Temperature and Humidity Cycling Test Conditions.

45、Samples of insulation shall be aged 168 hour in an oven at the test temperature shown in Figure 6 Mechanical Properties and Temperature and Humidity Cycling Test Conditions. After aging, the tensile strength shall not be less than 80% of the original test value and the elongation shall not be less t

46、han 50% of the original test value. SAE Cable Tensile Strength MPa Elongation % Test Temperature C Temperature Class Rating C Type Minimum Minimum Ref. Clause 6.3 Ref. Clause 6.16 TWP GPT HDT 11 125 110 r 2 80 r 2 HTS 7 150 110 r 2 80 r 2 TXL GXL SXL 10 150 155 r 3 125 r 3 NOTE:The above accelerated

47、 aging temperatures are appropriate for insulating materials currently specified in this standard. Different test conditions may be necessary for other materials. Figure 6 - “Mechanical properties” and “temperature and humidity cycling”, test conditions 6.4 Dielectric 25 mm of insulation shall be re

48、moved from each end of a 600 mm sample of finished cable and the two ends twisted together. The loop thus formed shall be immersed in water containing 5% salt by weight at room temperature so that not more than 150 mm of each end of the sample protrudes above the solution. After being immersed for 5

49、 hours and while still immersed, the sample shall withstand the application of 1000 V rms at 50 to 60 Hz between the conductor and the solution for 1 minute without failure of the insulation. SAE INTERNATIONAL J1128 DEC2015 Page 12 of 24 6.5 Insulation Faults This is an in-process test intended for mass production of all cable covered in this document. The test electrode shall be of the link