SAE J 2192-2016 Recommended Testing Methods for Physical Protection of Wiring Harnesses.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 2016 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/J2192_201606 SURFACE VEHICLE RECOMMEDNED PRACTICE J2192 JUN2016 Issued 2005-05 R

5、evised 2016-06Superseding J2192 MAR2015 Recommended Testing Methods for Physical Protection of Wiring Harnesses RATIONALE This recommended practice is being revised to remove references to the LV312 German tape specification, which is not readily obtainable by anyone not doing business with German a

6、uto manufacturers. TABLE OF CONTENTS 1. SCOPE 2 1.1 Application . 2 2. REFERENCES 2 2.1 Applicable Documents 2 3. GLOSSARY 3 4. QUALITY REQUIREMENTS . 4 4.1 Product Quality Assurance . 4 5. CLASSIFICATION (TEMPERATURE IDENTIFICATION) 4 6. TESTING METHODS 4 7. TESTS PROCEDURES 5 7.1 Sampling . 5 7.2

7、Sample/Specimen Preparation . 5 7.3 Heat Aging 6 7.4 Temperature/Humidity Cycling 6 7.5 Flammability 7 7.6 Low Temperature Flexibility 7 7.7 Fluids Resistance 7 7.8 Fogging . 8 7.9 Component Compatibility 8 7.10 Noise Suppression 8 7.11 Abrasion Resistance . 11 7.12 Puncture/Pinch 12 7.13 Dynamic Cu

8、t-Through . 12 7.14 Impact Resistance Test (Convolute Only) 12 7.15 Thermal Insulation . 13 7.16 Dielectric Test . 13 8. PRODUCT APPEARANCE AND QUALITY 13 SAE INTERNATIONAL J2192 JUN2016 Page 2 of 14 9. SUPPLIER RESPONSIBILITY 13 10. TOXICOLOGY CONFORMANCE . 13 11. PRODUCT APPROVAL 13 12. NOTES 14 1

9、2.1 Revision Indicator 14 Figure 1 Test setup 9 Figure 2 Picture of test setup 9 Figure 3 Rattling test set-up 10 Figure 4 Rubbing test set-up . 11 Figure 5 Apparatus for impact resistance test . 12 Table 1 Temperature classifications 4 Table 2 Testing methods and their applicability to covering cat

10、egories and classes 5 Table 3 Test temperature for heat aging and temperature/humidity cycling 6 Table 4 Cycling sequence for temperature/humidity cycling test . 7 Table 5 Fluids to be used for fluids compatibility test 8 1. SCOPE This SAE Recommended Practice describes the recommended methods for t

11、esting flexible harness coverings for use on ground vehicle electrical distribution systems. This Recommended Practice shall apply to all tapes, extruded tube and textile tube. 1.1 Application This document shall be applied for coverings used on wiring assemblies. The Customers Engineering Group mus

12、t approve material based on the functional application performance requirements to assure proper validation of covering materials. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the lates

13、t 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 Canada) or +1 724-776-4970 (outside USA), www.sae.org. SAE ARP1536A Abrasion Test Procedure for Chafe Guard SAE J311

14、Fluid for Passenger Car Type Automatic Transmissions SAE J369 Flammability of Polymeric Interior Materials - Horizontal Test Method SAE J1128 Low Voltage Primary Cable SAE J1756 Determination of the Fogging Characteristics of Interior Automotive Materials SAE J2302 Thermal Effectiveness of Sleeve In

15、sulation SAE J2495 Thermal Containment Efficiency of Sleeve Materials SAE INTERNATIONAL J2192 JUN2016 Page 3 of 14 2.1.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org ASTM D 471 Standard Te

16、st Method for Rubber Property - Effect of Liquids ASTM D 3032 Standard Test Methods for Hookup Wire Insulation, Section 22 - Dynamic Cut Through ASTM D 4157 Test Method for Abrasion Resistance of Textile Fabrics ASTM D 5423 Forced-Convection Laboratory Ovens for Evaluation of Electrical Insulation A

17、STM F 1306 Test Method for Slow Rate Penetration Resistance of Flexible Barrier Films 2.1.3 ISO Publications Copies of these documents are available online at http:/webstore.ansi.org/ ISO 3795 Road Vehicles, and Tractors and Machinery for Agriculture and Forestry - Determination of Burning Behavior

18、of Interior Materials ISO 6722-1 Road Vehicles - 60 V and 600 V Single-Core Cables - Dimensions, Test Methods and Requirements Applicable Quality Standards (e.g., QS 9000, ISO/TS16949, etc.) 3. GLOSSARY 3.1 FUNCTIONALITY Performs to design intent. 3.2 DEGRADATION Loss of functionality due to physica

19、l changes such as cracks, tears, melting or other forms of reduction in material strength, composition or integrity. 3.3 EXTERIOR APPLICATION Applications outside the passenger compartment 3.4 INTERIOR APPLICATION Applications inside the passenger compartment. 3.5 RECOMMENDED PRACTICES Suggested tes

20、t method that does not include specification limits. 3.6 TAPE A continuous strip of cloth, fabric, metal, paper or plastic material with or without adhesive. 3.7 EXTRUDED TUBE Tubes, plain or profiled, including convoluted tubings, that are extruded from elastomers, metals, plastics, or combination

21、of materials. SAE INTERNATIONAL J2192 JUN2016 Page 4 of 14 3.8 TEXTILE TUBE Tubes that are made with textile materials. 3.9 SPECIMEN The combination of one or more coverings applied to a wire bundle, where the coverings and wires are specified by the customer. In some instances, the coverings may be

22、 applied to a mandrel. 3.10 SAMPLE The coverings being tested using the methods in this Recommended Practice. The combination of samples applied to a wire bundle form a specimen. 3.11 BUNDLE Short for “wire bundle”; consists of a grouping of wires prepared in accordance with 7.2. When samples of one

23、 or more coverings are applied to a wire bundle, the combination becomes a specimen. 4. QUALITY REQUIREMENTS 4.1 Product Quality Assurance Product Quality Assurance must follow the requirements and be in compliance with the applicable Quality Standard. 5. CLASSIFICATION (TEMPERATURE IDENTIFICATION)

24、Temperature requirement is by class as noted in Table 1. It is the responsibility of the customer to determine the “Class“ to be used for any application. Temperature ratings are to be considered the minimum service temperature required. It is the responsibility of the supplier to properly designate

25、 the service temperature of their product and provide the necessary data to the performance criteria in this specification when submitting to the customer for approval. Verification of any and all of the data submitted by the supplier is at the discretion of the customer. Table 1 - Temperature class

26、ifications Class Temperature (C) Class A 40 to 85 Class B 40 to 100 Class C 40 to 125 Class D 40 to 150 Class E 40 to 175 Class F 40 to 200 Class G 40 to 225 Class H 40 to 250 6. TESTING METHODS The recommended test methods are found in Table 2. SAE INTERNATIONAL J2192 JUN2016 Page 5 of 14 Table 2 -

27、 Testing methods and their applicability to covering categories and classes Test Category Applicable Class and/or Application Test Method Tape Extruded Tube Textile Tube Heat Aging X X X All 7.3 Temperature/Humidity X X X All 7.4 Flammability X X X All 7.5Low Temperature Flexibility X X X All 7.6 Au

28、tomotive Fluids Resistance X X X For Exterior Applications Only 7.7 Fogging X X X For Interior Applications Only 7.8 Component Compatibility X X X Customer Designated 7.9 Noise Suppression X X X Customer Designated 7.10 Abrasion Resistance X X X Customer Designated 7.11 Puncture/Pinch X X Customer D

29、esignated 7.12Cut Through X X X Customer Designated 7.13 Impact X Customer Designated 7.14Thermal Insulation X X X Customer Designated 7.15 7. TESTS PROCEDURES 7.1 Sampling If it is not specified, the sample size must be five. The suggested dimension of the sample is 10 mm minimum, however, if the m

30、anufacturer is supplying sizes other than 10 mm, the customer may request other sample sizes. Selection must be representative of the current production for each test and test results should be reported. Precondition/equilibrate dry samples to 23 C 5 C and 50% 5% relative humidity for a minimum of 2

31、4 hours prior to testing unless otherwise noted. 7.2 Sample/Specimen Preparation 7.2.1 Tape Assemble a bundle of wire 300 mm or greater (300 to 450 mm recommended) in length of an appropriate number and size to approximate a diameter of 10 mm as designated by customer. Wire sizes and insulation type

32、s will be specified by the customer. If specified, cover the bundle with a piece of 10 mm diameter convoluted tubing of the same length as the bundle. Note that for the Heat Aging and Temperature/Humidity Cycling tests, the appropriate wire type and tubing with the same operation temperature as the

33、tape in question must be used; for other tests, it may be appropriate to use wire types and/or tubing with different operation temperatures. Wrap the tape to be tested around the bundle with a 50% overlap. 7.2.2 Extruded Tube Assemble a bundle of wire 300 mm or greater (300 to 450 mm recommended) in

34、 length of wire of an appropriate number and size to approximate a diameter of 10 mm or as specified by customer; in the absence of such specification, assemble the bundle so that its diameter is 80% of the diameter of the tubing to be tested. Wire sizes and insulation types will be specified by the

35、 customer. Cover the bundle with a piece of extruded tube of the same length as the bundle. Note that for the Heat Aging and Temperature/Humidity Cycling tests, the appropriate wire type with the same continuous operating temperature must be used with the extruded tube being tested as specified by t

36、he customer or test method; for other tests, it may be appropriate to use wire types with different operation temperatures. SAE INTERNATIONAL J2192 JUN2016 Page 6 of 14 7.2.3 Textile Tube Assemble a bundle of wire 300 mm or greater (300 to 450 mm recommended) in length of an appropriate number and s

37、ize to approximate a diameter of 10 mm or as specified by customer; in the absence of such specification, assemble the bundle so that its diameter is 80% of the diameter of the tubing to be tested. Wire sizes and insulation types will be specified by the customer. Cover the bundle with a piece of te

38、xtile tube of the same length as the bundle. Note that for the Heat Aging and Temperature/Humidity Cycling tests, the appropriate wire type with the same continuous operating temperature must be used with the textile tube being tested as specified by the customer or test method; for other tests, it

39、may be appropriate to use wire types with different operation temperatures. 7.3 Heat Aging 7.3.1 The material shall withstand temperature according to class noted in Table 3, and tested according to the procedure described in 7.3.2. 7.3.2 Place 30 pieces of 450 mm long test specimens of each sample

40、in a forced air convection oven (Type II as specified in ASTM D 5423, with air exchange rate of 100 to 200 per hour) at the sample maximum class temperature (refer to Table 3) for the duration of time interval. Table 3 - Test temperature for heat aging and temperature/humidity cycling Class Temperat

41、ure (C)Class A 85 2 Class B 100 2 Class C 125 3 Class D 150 3 Class E 175 3 Class F 200 3 Class G 225 4 Class H 250 4 7.3.3 At 500, 1,000, 1,500, 2,000, 2,500, and 3,000 hour intervals, remove five pieces of test specimens of each sample from the oven and condition them at 23 C 5 C and 50% 5% relati

42、ve humidity for at least 4 hours. 7.3.4 Wrap each of the conditioned test specimens around a mandrel with a diameter equal to four times the nominal ID of the test specimen at a uniform rate of one turn per 10 seconds. After 1,500 hours of heat aging and at 500-hours intervals to 3,000 hours, bend t

43、he specimens around a mandrel with a diameter equal to ten times the nominal ID of the test specimen at a uniform rate of one turn per 10 seconds. Visually inspect the sample on each specimen for any sign of degradation. Record and report any change in appearance and signs of degradation (e.g., crac

44、ks, melting, fading, etc.). Perform any quantitative measurements (e.g., length of any cracks or flagging sections, etc.) as requested by the customer. 7.4 Temperature/Humidity Cycling 7.4.1 Place test specimens in an environmental chamber and set the cycling sequence as following for three cycles.

45、Refer to SAE J1128 for complete description. SAE INTERNATIONAL J2192 JUN2016 Page 7 of 14 Table 4 - Cycling sequence for temperature/humidity cycling test Step Condition Duration Total Time 1 Increase Temperature from 23 C 5 C Dexron VI 50 3 Engine Coolant 50% distilled Water + 50% Ethylene Glycol 5

46、0 3 Battery Acid H2SO4, Specific Gravity = 1.260 0.005 23 5 Brake Fluid Diesel Emission Fluid SAE RM-66-04 ISO 22241 23 5 23 5 Table Note 1: Fluid availability may change over time. 7.7.3 Remove each specimen from test fluid and allow it to drain for 20 min. Let samples condition 23 C 5 C for 72 h.

47、7.7.4 Visually inspect the sample on each specimen for any sign of degradation after 1, 24, 48, and 72 hours. After 72 hours, wrap each specimen a complete 360 degrees around a mandrel with a diameter equal to four times the nominal ID of the test specimen at a uniform rate of one turn per 10 second

48、s. Record and report any change in appearance, signs of degradation or loss of flexibility. Perform any quantitative measurements (e.g., length of any cracks or flagging sections, etc.) as requested by the customer. 7.8 Fogging 7.8.1 Conduct the Fogging Test according to SAE J1756 using either the P

49、hotometric Method or the Gravimetric Method per agreement between customer and the supplier. 7.8.2 The test duration is to be specified by the customer. 7.8.3 Report Fog Number when using the Photometric Method; and Fog Mass when using the Gravimetric Method or as required by the customer. 7.9 Component Compatibility 7.9.1 Assemble components and test as specified by customer