SAE J 2222-2012 Coiled Electrical Cable - Truck and Bus《卡车和汽车用盘绕电缆》.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 there

2、from, 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 p

3、ublication 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: +1 724-776-497

4、0 (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/J2222_201210SURFACE VEHICLE STANDARD J2222 OCT2012 Issued 1993-11 Revised 2012-10

5、 Superseding J2222 JUN2007 Coiled Electrical Cable - Truck and Bus RATIONALE The rewrite of this document corrected procedural performance testing criteria in sections 4.3, 4.4 and 4.5. The section 4.3 (Force to extend) rewrite involved interchanging the relaxed and working length of the coiled elec

6、trical cable in the test sequence. The section 4.4 and 4.5 rewrites (Sag and endurance), involved providing the correct flex cycle section (4.7) in the test procedure. Section 4.4 also added section 3.6 to define sag. FOREWORD A Draft Technical Report under this number was published in November of 1

7、993. The purpose of that document was to give the technical community the opportunity to review, comment on and use the document and to complete the development of the related SAE J2394 Seven Conductor Cable for ABS Power Standard, which has since been published. This new document is a Standard that

8、 includes reference to the appropriate cable Standards and takes into consideration the information and experience gathered from the use of the Draft Report. Among the key objectives in the development of this new document was to improve the cables resistance to sag as this has been a major contribu

9、tor to field failures. Enhancements to the SAE J560 Standard such as the establishment of an angular pull force requirement and an increase in the allowable latched connector detachment force, have aided this objective by relieving the force to extend requirement in this document. Other industry gui

10、delines and recommended practices also contributed to the development of this document. 1. SCOPE This SAE Standard establishes the minimum performance and endurance requirements for coiled electrical cables used for hookup between trucks, trailers and dollies. The component standards SAE J2394 (repl

11、aced SAE J1067) for cable and SAE J560 for connectors must be consulted to determine the complete performance and endurance requirements of the system. Related TMC Recommended Practices may be consulted for information associated with selection, installation and inspection of these coiled electrical

12、 cables. This document is intended to set out requirements for the majority of conditions rather than for specialized applications or environments. SAE J2222 Revised OCT2012 Page 2 of 6 2. REFERENCES 2.1 Applicable Documents The following publications form a part of the specification to the extent s

13、pecified herein. Unless otherwise indicated the latest revision 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 724-776-4970 (outside USA), www.sae.org. SAE J560

14、Primary and Auxiliary Seven Conductor Electrical Connector for Truck-Trailer Jumper Cable SAE J2394 Seven Conductor Cable for ABS Power Truck and Bus 2.2 Related Publications The following publications are provided for information purposes only and are not a required part of this SAE Technical Repor

15、t. 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 724-776-4970 (outside USA), www.sae.org. SAE J702 Brake and Electrical Connection Locations - Truck-Tractor and Truck-Trailer SAE J1067 Seven Co

16、nductor Cable Truck and Bus 2.2.2 TMC (Technology and Maintenance Council) Publications Available from Technology and Maintenance Council, American Trucking Associations, 950 N Glebe Rd., Suite 210, Arlington, VA 22203-4181, Phone: (703) 838-1763, Fax: (703) 838-1701, . RP 107C Seven Conductor Truck

17、-Trailer Converter Dolly Jumper Cable and Connector System RP137C Antilock Electrical Supply from Tractors through the SAE J560 Seven Pin Connector RP141 Trailer ABS Power Supply Requirements RP 159 Installation and Inspection Guidelines for Seven Conductor Truck-Trailer/Converter Dolly Jumper Cable

18、 and Connector RP 703B Electrical and Gladhand Connector Placement SAE J2222 Revised OCT2012 Page 3 of 6 3. DEFINITIONS 3.1 COILED ELECTRICAL CABLE The coiled electrical cable consists of seven conductor cable described by SAE J2394 (Type FFlexing) that has been formed into a cylindrical helix. The

19、electrical connector, (plug), specified in SAE J560 may terminate one or both ends of the cable to form an assembly. 3.2 COILED SECTION The coiled section of the cable is that section which is formed into a helix. It excludes the lead lengths. 3.3 LEAD LENGTH Lead length refers to the straight, non-

20、coiled section, including connector plug at either end of a coiled electrical cable assembly. 3.4 WORKING LENGTH Working length is the term referring to the manufacturers published rating of the distance over which the coiled cable can be extended in the tractor-trailer application (Refer to Figure

21、1). It is defined here as the extended length of the coiled electrical cable from the beginning of the first coil loop at the tractor end of the cable where the cable will be clamped, to the end of the lead length at the SAE J560 trailer interface connector (Refer to Figure 2). FIGURE 1 - CABLE WORK

22、ING LENGTH SAE J2222 Revised OCT2012 Page 4 of 6 FIGURE 2 - ALTERNATE CABLE SUSPENSION METHODS AND WORKING LENGTH MEASURING POINTS 3.5 RELAXED LENGTH Relaxed length refers to the length of the coiled electrical cable when a tractor and trailer are in a straight position with the tractor lead clamped

23、 and the trailer connector engaged. For purposes of testing, this length is assumed to be equal to one third of the working length (Refer to Figure 2 above). 3.6 SAG Sag refers to the vertical drop measured from the horizontal centerline to the lowest point on the coiled section of the assembly. 3.7

24、 COIL FLEX CYCLE A coil flex cycle is defined as stretching the coiled cable section to 75% of its working length and then returning it to its relaxed length within 15 s 2 s. 4. TESTING AND PERFORMANCE SPECIFICATIONS 4.1 Test Sequence All tests shall be executed in the order specified herein with th

25、e same physical cable assembly sample used in each successive test SAE J2222 Revised OCT2012 Page 5 of 6 4.2 Electrical 4.2.1 Measure the mV drop at 10.0 A 0.10 A across each conductor and calculate the resistance based on these measurements. 4.2.2 Adjust a Hipot for 0.5 mA current detection. Apply

26、500 V AC with the Hipot between the red conductor and the other six conductors for 1 min. Stretch the coil to the working length once during this 1 min test. Repeat the test six times for blue, brown, green, yellow, black and white conductor. 4.3 Force to Extend This test is primarily intended to en

27、sure that the force required to extend the trailer cable will not cause the SAE J560 connectors to inadvertently disengage while a tractor is making a severe right-hand turn in cold weather conditions. Current (low) mounting locations require that the tractor lead length be clamped (Refer to Figure

28、2 above), providing secondary strain relief here. The trailer connectors are subject to an angular pull force, the performance requirements for which are outlined in SAE J560. The extent of the pull is consistent with TMC guidelines. A pull to the full working length has also been included to allow

29、in case of misapplication to beyond the TMC guidelines ensuring that such a condition will not cause a pull force that exceeds the SAE J560 connector capabilities. Stretch the relaxed length as defined in 3.5, of the coiled electrical cable to the defined working length as defined in 3.4 at a 20 C 5

30、 C (68 F) ambient temperature and measure the pull force at that point. The force required shall not exceed 157 N (35 lb). Then to simulate normal conditioning of a cable, stretch it for one coil flex cycle as defined in 3.7. Then install this working section of the coiled electrical cable in a fixt

31、ure that stretches it to its relaxed length simulating a cable hooked up in a straight tractor-trailer connection and insert the fixture in a low-temperature chamber (40 C 2 C) (40 F) for 4 hours. After conditioning, measure the force to stretch the cable to 75% and then to 100% of the working lengt

32、h within 15 s after removing it from the chamber. The force required shall not exceed 535 N (120 lb) and 667 N (150 lb) respectively. 4.4 Sag Resistance To simulate normal use, install the working length (3.4), of the coiled electrical cable at the defined relaxed length (3.5), into a fixture and ho

33、ld for 4 hours in a chamber at (43 C 2 C) (110 F). Remove the cable from the chamber and allow it to cool for 5 min at a 20 C 5 C (68 F) ambient temperature. At this point, while the cable is still in the fixture, measure the sag (3.6). The maximum allowable sag is 50 cm (20 inches). Temporarily rem

34、ove the cable from the fixture and stretch it for one flex cycle (3.7). This simulates a right hand turn. Return the cable to the fixture. After 5 min, measure the sag. The maximum allowable sag is 50 cm (20 inches) keeping the cable sufficiently away from the tractors deck. 4.5 Endurance Subject th

35、e coiled electrical cable to 200 000 coil flex cycles as defined in (3.7) at a 20 C 15 C (41 F to 95 F) ambient temperature. 4.6 Electrical 4.6.1 Repeat electrical hipot tests 4.2.1 and 4.2.2 upon completion of the above battery of tests. 4.6.2 The coiled cable shall not exceed a 5% resistance incre

36、ase when compared to 4.2.1 4.6.3 The coiled cable shall pass the Hipot tests and shall exhibit no visible signs of operational failure. SAE J2222 Revised OCT2012 Page 6 of 6 5. GENERAL SPECIFICATIONS 5.1 Environment Resistance It is assumed that the coiled section of the cable will be mounted extern

37、ally. Coiled cables that are expected to be routed in a fashion that exposes any portion of the cables to a more severe environment (e.g., high heat), should be subjected to additional testing to confirm the coiled cables suitability in that environment. 5.2 Related Applications The performance requ

38、irements outlined in this Document should be considered for coiled cables of other than the 7-way type, (e.g., liftgate cables) as well. 5.3 Marking Cable assemblies conforming to this document shall be identified either in the form of a tag or label affixed to the assembly or package that needs not

39、 endure for the life of the assembly, with at least the following information to assure the purchaser of compliance to this Document. a. Manufacturers name or symbol b. Working Length (including units in ft) c. “SAE J2222-” and year of manufacture 6. NOTES 6.1 Marginal Indicia A change bar (l) locat

40、ed in the left margin is for the convenience of the user in locating areas where technical revisions, not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left of the document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original publications, nor in documents that contain editorial changes only. PREPARED BY THE SAE TRUCK AND BUS ELECTRICAL SYSTEMS COMMITTEE