SAE J 1614-2012 Wiring Distribution Systems for Off-Road Self-Propelled Work Machines《越野自驱动式工作机的布线分布系统》.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 theref

2、rom, 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 2012 SAE International All rights reserved. No part of this pub

3、lication 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: +1 724-776-4970

4、(outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J1614_201209SURFACEVEHICLERECOMMENDEDPRACTICEJ1614 SEP2012 Issued 1998-03Revised 201

5、2-09Superseding J1614 MAY2010 Wiring Distribution Systems for Off-Road, Self-Propelled Work Machines RATIONALEElectrical wiring systems are becoming large and complex. There is a desire to reduce cable size to address large wiring system bundle sizes and also to address wiring to components that hav

6、e small integral electrical connectors. OEMs with machine or tractor designs produced in multiple global locations may desire the use of ISO 6722-1 cable sizes to facilitate local wiring system manufacture outside of North America. This standard is being revised to address the potential use of small

7、er cable sizes and ISO 6722-1 cable types required by current and future off-road, self-propelled earthmoving machines and agricultural tractors. Additional changes include correction to cable resistances and 1 volt drop run lengths, addition of data for smaller cable sizes and ISO 6722-1 cable type

8、s, added references to SAE AWG size, and added a section on Battery Disconnect Switch. 1. SCOPE This SAE Standard specifies requirements and design guidelines for electrical wiring systems of less than 50 V and cable diameters from 0.35 to 19 mm2used on off-road, self-propelled earthmoving machines

9、as defined in SAE J1116 and agricultural tractors as defined in ASAE S390. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. SAE J1614 Revis

10、ed SEP2012 Page 2 of 20 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.SAE J163 Low Tension Wiring and Cable Terminals and Splice Clips SAE J378 Marine Pr

11、opulsion System Wiring SAE J553 Circuit Breakers SAE J1116 Categories of Off-Road Self-Propelled Work Machines SAE J1127 Low Voltage Battery Cable SAE J1128 Low Voltage Primary Cable SAE J1493 Guarding of Starter System Energization SAE J1908 Electrical Grounding Practice 2.1.2 IEC Publication Avail

12、able from International Electrotechnical Commission, 3, rue de Verambe, P.O. Box 131, 1211 Geneva 20, Switzerland, Tel: +41-22-919-02-11, www.iec.ch.IEC 617 Graphical Symbols for Diagrams 2.1.3 ASABE Publication Available from ASABE, 2950 Niles Road, St. Joseph, MI 49085-9659. ANSI/ASAE S390 Definit

13、ions and Classifications of Agricultural Equipment 2.1.4 DIN Publication Available from Deutsches Institut fur Normung, Postfach 1107, D-1000 Berlin 30, Germany DIN 76 722 Road Vehicles, Low tension cables, Composition of type codes 2.1.5 ISO Publication Available from International Organization for

14、 Standardization, 1, rue de Varembe, Case postale 56, CH-1211 Geneva 20, Switzerland, Tel: +41-22-749-01-11, www.iso.org.ISO 6722-1 Road vehicles 60 V and 600 V single-core cables Dimensions, test methods and requirements ISO 9247 Earth-moving machinery Electrical wires and cables Principles of iden

15、tification and marking 2.1.6 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Boc C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org.ASTM B 1 Standard Specification for Hard-Drawn Copper Wire SAE J1614 Revised SEP2012 Page 3 of 20 2.2 Related Publ

16、ications 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 (inside USA and Canada) or 724-776-497

17、0 (outside USA), www.sae.org.SAE J562 Nonmetallic Loom SAE J821 Electrical Wiring Systems for Construction, Agricultural, and Off-Road Machines 3. DEFINITIONS 3.1 ELECTRICAL CIRCUITS An electrical circuit includes all the components and connecting cables, starting from the electrical energy source,

18、going to the functional component(s) and the return route to the energy source. 3.2 ELECTRICAL COMPONENT An electrical component is normally a combination of parts, sub-assemblies, or assemblies and is a self-contained element intended to store, generate, distribute, alter, or consume electrical ene

19、rgy. 3.3 CONDUCTOR(S) The current carrying element(s) in a cable. 3.4 ELECTRICAL CABLE Insulated stranded electrical conductor used to establish a single current path. 3.5 HARNESS A group of two or more cables bundled together. 3.6 TERMINAL An electrically conductive device attached to a cable to fa

20、cilitate connection to an electrical component, cable, or termination.3.7 CONNECTOR A coupling device which provides an electrical and/or mechanical junction between two cables or between a cable(s) and an electrical component. 3.8 WIRING Collectively, the cables, harnesses, connectors, terminations

21、, and supporting components used in the electrical wiring distribution system. SAE J1614 Revised SEP2012 Page 4 of 20 4. WIRING DESIGN 4.1 Cable Selection The preferred cable shall meet the requirements of SAE J1127 type SGX and SAE J1128 type SXL. Other cable types may be required for specific appl

22、ications. When changing cable sizes from SAE J1128 to ISO 6722-1, the cross-sectional area of the conductor will change. SAE J1128 specifies minimum cross-sectional area which is different than the SAE “cable size”. ISO 6722-1 specifies minimum electrical resistance and references nominal conductor

23、cross-sectional area. When changing from one specification to the other, it is necessary when the copper cross-sectional area is reduced to repeat the cable size selection process as specified in Section 4 of this specification to ensure adequate current carrying capability and meet maximum allowabl

24、e voltage drop. When changing cables sizes from SAE J1128 to ISO 6722-1, the wiring system designer will also need to verify that the selected terminals conductor crimp range will accept the alternative conductor diameter. The cable insulation thickness is also different so that the cable seal diame

25、ter range for the connector must also be reviewed to ensure sealing to the new cable diameter and that the terminals insulation crimp range is within tolerance. The insulation naming convention for ISO 6722-1 cables can be found in DIN 76 722. The near equivalent to SAE type XLPO cable insulation is

26、 DIN 76 722 type FL2X. 4.2 Cable Size Determination Cable size is determined by consideration of the following factors: a. Cable mechanical strength b. Maximum temperature rise c. System voltage drops d. Selected connectors 4.2.1 Apply the procedure in Figure 1, Cable Sizing Flowchart, for determini

27、ng cable sizes. These factors vary in importance depending upon the application. Details specific to each are found in the following paragraphs.4.2.1.1 Configure the electrical circuit including grounds and connectors. 4.2.1.2 Determine current requirements and cable lengths. 4.2.1.3 Determine fuse,

28、 circuit breaker, or other requirements applying appropriate de-rating factors. 4.2.1.4 A minimum size cable, or larger, shall be selected which meets all the previous requirements. 4.2.2 For mechanical strength, the minimum cable size recommended shall be 0.8 mm2in harnesses and/or protected areas

29、in exterior or unprotected interior applications. A cable size of 1 mm2shall be the minimum cable size in areas susceptible to physical damage, or where one or two cables are extended from the harness. For protected areas within an enclosed compartment such as a cab or operator accessible electronic

30、 enclosure, the minimum cable size shall be 0.35 mm2.SAE J1614 Revised SEP2012 Page 5 of 20 FIGURE 1 - CABLE SIZING FLOWCHART 4.2.3 The maximum temperature of the cable with steady-state currents shall not exceed the continuous duty temperature rating of the cable insulation, connector molding mater

31、ial, or other materials which the cable may come in contact with. 4.2.4 Fault Condition Maximum Temperature Rise 4.2.4.1 To control maximum temperature rise in a fault condition the cable must be sized for the circuit protection installed in the circuit. When a circuit breaker is used, it is importa

32、nt that the cable and the breaker be sized in such a way that the thermal circuit breaker “heats“ at a rate higher than the cable to protect the cable from damage. Table 1 lists the minimum cable sized for given thermal circuit breakers. Table 1 is intended for manual reset breakers but can also be

33、used for fuses. Auto-reset breakers require additional consideration to prevent overheating. See SAE J553 for additional guidance. In ambient temperatures up to 65 C, the circuit breaker must be de-rated typically to 70% of its rating to prevent possible opening under steady-state conditions. In a f

34、ault condition, it is typical for the temperature of the cable to be raised by the fault current in the cable. SAE J1614 Revised SEP2012 Page 6 of 20 TABLE 1 - CABLE SIZED FOR THERMAL CIRCUIT BREAKERS 70% Load Operating Current (A)Circuit Breaker Rating (Thermal type) (A)Smallest SAE Cable Size Acce

35、ptable (mm2/AWG)Calculations for this column are found in Appendix A. 2.8 4.0 0.35 / 22 3.5 5.0 0.5 / 20 5.2 7.5 0.8 / 18 7.0 10 1 / 16 10.5 15 2 / 14 14 20 3 / 12 21 30 5 / 10 28 40 8 / 8 42 60 13 / 6 56 80 19 / 4 4.2.5 For Steady-State Thermal Capacity, the selected cable size should be verified b

36、y load testing. Table 2 gives the values of currents permissible based on the assumptions of 30 C rise for cables bundled in a harness and 10 C rise of a single cable in free air due to steady-state current heating. Circuit protection should be sized for the smaller size cable within the circuit. TA

37、BLE 2 - STEADY-STATE THERMAL CAPACITY(1)SAE Cable Size (mm2/AWG) SAE Ratings (A) 0.35 / 22 4.0 0.5 / 20 5.5 0.8 / 18 7.5 1 / 16 10 2 / 14 14 3 / 12 20 5 / 10 29 8 / 8 41 13 / 6 60 19 / 4 82 1. Dimensions used in calculating this table are typical industry values. Values found in this table are based

38、 on the calculations found in Appendix A.4.2.6 Intermittent Load Cycles For circuits where the electrical load is of a short duration, a 90-s rating can be used. As an example, a cable which is at a 40 C ambient and is allowed to thermally rise to 150 C. A short-term rating can be calculated based o

39、n its thermal mass. Based on the formula 82.13AreaCurrent=, the following ratings and sizings would be established. Please see Appendix A for the derivation of the constant. 8 mm2is rated 90 A 13 mm2is rated 160 A 19 mm2is rated 250 A SAE J1614 Revised SEP2012 Page 7 of 20 4.2.7 The procedure used t

40、o determine voltage drop with respect to cable size begins with establishing maximum allowable voltage drop VD (volts), length of cable l (mm), and maximum operating current in circuit i (A). 4.2.7.1 Calculate cable resistance in micro-ohms/mm (r) as shown in Equation 1: 610liVDr = (Eq. 1) 4.2.7.2 A

41、fter finding the calculated resistance, select the cable size from Table 3 or referring to ISO 6722-1 for additional ISO 6722-1 conductor sizes. TABLE 3 - VOLTAGE DROP RESISTANCE SAE Cable Size (mm2/AWG)SAE Maximum Resistance(/mm) ISO Cable Size(mm2)ISO Maximum Resistance(/mm) 19 / 4 0.94 16 1.16 13

42、 / 6 1.43 10 1.82 8 / 8 2.39 5 / 10 3.71 5 3.94 3 / 12 5.93 3 6.15 2 / 14 9.32 2 9.42 1 / 16 15.4 1 18.5 0.8 / 18 22.7 0.75 24.7 0.5 / 20 33.9 0.50 37.1 0.35 / 22 53.2 0.35 54.4 NOTE: ISO 6722-1 specified maximum cable resistance is about 8% higher than if calculated from the nominal diameter. SAE J

43、1128 specifies the minimum cable cross-sectional diameter so the theoretical maximum resistances were calculated per ASTM B 1. Examples of typically acceptable run lengths with a 1 V drop in a 12 V system are given on Tables 4a and 4b. Please note certain systems require voltage drops as small as 0.

44、1 V. Calculation of the full system voltage drop is always recommended. (Note: run length is of loop length.) Maximum voltage drop shall be established to provide optimum performance and reliability of the components, e.g., voltage sensitive devices.SAE J1614 Revised SEP2012 Page 8 of 20 TABLE 4A -

45、TYPICAL 1 V DROP RUN LENGTHS FOR SAE J1128 CABLE SIZES 0.35 / 220.5 / 200.8 / 181 /162 /143 /125 /108 / 813 /619 /4SAE Size (mm2/AWG)Amperage (amps) 2.5 3.8 5.9 8.8 13 22 34 54 84 140 212 5 2.9 4.4 6.5 11 17 27 42 70 106 7.5 2.9 4.3 7.2 11 18 28 47 71 10 2.2 3.2 5.4 8.4 14 21 35 53 12.5 2.6 4.3 6.8

46、11 17 28 43 15 3.6 5.6 9.0 14 23 35 20 2.7 4.2 6.7 11 18 27 25 3.4 5.4 8.4 14 21 30 2.8 4.5 7.0 12 18 Marginal Acceptable TABLE 4B - TYPICAL 1 V DROP RUN LENGTHS FOR ISO 6722-1 CONDUCTOR SIZES 0.35 0.5 0.75 1 2 3 5 10 16 ISO Size (mm2)Amperage (amps) 2.5 3.7 5.3 8.0 11 21 32 54 107 172 5 2.7 4.0 5.3

47、 11 16 27 54 86 7.5 2.7 3.6 7.1 11 18 36 57 10 2.0 2.7 5.3 8.0 13 27 43 12.5 2.1 4.3 6.4 11 21 34 15 3.6 5.3 8.9 18 29 20 2.7 4.0 6.7 13 21 25 3.2 5.4 11 17 30 2.7 4.5 8.9 14Marginal Acceptable 4.2.8 Procedure for Resistance Budget a. Determine entire voltage drop that is acceptable from the positiv

48、e terminal of the battery to the negative terminal of the battery. b. Divide the voltage drop by the anticipated current draw of the load to calculate the entire resistance that is tolerable (“Resistance Budget“). c. Subtract known resistance values from the budget amount. Suppliers of components sh

49、ould be able to provide component specifications. If not, they can be measured or estimated by considering electrical contact junctions equal to 1 m per contact and internal switch contacts equal to 8 m each. d. Divide the remaining resistance by the distance to and from the load. This is the “Maximum Allowable Resistance“. e. Use Table 3 to determine the cable size needed based on resist