1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 08 18 Revised Para 3.0 inserted; Para 3.1, 3.5, 3.20, 4 deleted 1994 03 18 EE00E10370193000 Pages 1,7, 8 & 9 Rev MD/ME-20 H. Lehmacher 1990 10 23 EE00I10051754002 Released MD/PL-10 U. Schwarz Printed copies are uncontrolled Copyright 2003
2、, Ford Global Technologies, Inc. Page 1 of 9 CABLE, LOW TENSION, TPE INSULATED, 150 C, WSK-M1L126-A1 THIN WALL, BARE CABLE, LOW TENSION, TPE INSULATED, 135 C, WSK-M1L126-A2 THIN WALL, BARE CABLE, LOW TENSION, TPE INSULATED 135 C, WSK-M1L126-A3 THIN WALL, TINNED 1. SCOPE The material defined by these
3、 specifications is a low tension stranded cable, thermoplastic elastomer (TPE) insulated conductor. The cable is similar to ISO 6722 with a thin wall insulation thickness. 2. APPLICATION These specifications were released originally for materials used in automotive electrical harnesses. Note: The as
4、semblers of electrical wire harnesses shall use the bulk wire suppliers as shown in the Ford Motor Company Approved Source List. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production
5、Materials (WSS-M99P1111-A). 3.2 CABLE 3.2.1 Specimen Length 1.2 m 3.2.2 The maximum outside diameter shall be determined by taking measurements at three points along the conductor length separated by at least 100 mm and recording the greatest overall diameter at each point. No single value shall exc
6、eed the maximum overall diameter as specified in Table 2. 3.3 CONDUCTOR 3.3.1 The conductor of all cable classes shall consist of bunched or stranded soft annealed copper wires. 3.3.2 Specimen Length 1.2 m 3.3.3 Three sections 10 mm long and separated by at least 400 mm shall be cut from the specime
7、n. Carefully remove the conductor without deformation of the insulation. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L126-A1/A2/A3Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 9 3.3.4 The conductor diameter shall be determined by measuring the inside diameter o
8、f the insulation taken at three points separated by at least 100 mm and recording the maximum inside diameter at each point. The measurements shall be made with an optical device accurate to at least 0.01 mm. No value shall exceed the maximum diameter of the conductor specified in Table 2. 3.3.5 The
9、 conductor area may be determined by measuring individual strand diameters and calculating the sums of the individual strand areas. As an alternate method, conductor area may also be determined in accordance with FLTM BB 105-01 or by measuring the resistance in accordance with tables 1a and 1b. 3.3.
10、6 The strands shall be bunched and the maximum lay length shall be a maximum of 50 times the conductor diameter. Minimum number of wires shall comply with Tables 1 and 2. Maximum variation between individual strand diameters must not exceed 10 percent per the following: Variation = max strand dia mi
11、n strand dia Min strand dia Missing strands are not allowed. 3.3.7 Elongation (ASTM B 3) for d 15% for d 0.287 mm e 20% where : d = individual strand diameter e = elongation of individual strand. 3.3.8 Resistivity, max (ASTM B 193, at 20 C Bare 1.7094 /cm Tinned 1.7544 /cm 3.4 INSULATION 3.4.1 The i
12、nsulating material shall be a thermoplastic elastomer (TPE) material, homogeneous in character. The surface shall be smooth and even without cracks, knots, blisters, or other faults. 3.4.2 The color of the cables are per the Munsell Color Coding System and shall conform to Table 3. The following met
13、hod shall be used to evaluate the color of the cables. Comparison must be made by a person with normal or corrected vision, under cool white fluorescent lighting. The surface being inspected and the tolerance set must be in the same plane. Cable samples must be placed flat, overlapping the color sta
14、ndard. Color tolerance Reference Sets are available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096. As an alternative, the color of the cables can be per the DIN 47002 or IEC 304 and shall conform to Table 4. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L126-A1/A2/A3Printed copies are uncontrolle
15、d Copyright 2003, Ford Global Technologies, Inc. Page 3 of 9 3.4.3 The minimum insulation thickness shall be determined by taking measurements at three points separated by at least 100 mm and recording the minimum insulation thickness at each point. The thickness shall be measured with an optical de
16、vice accurate to at least 0.01 mm. No single value shall be lower than the minimum insulation thickness specified in Table 2. 3.6 FAULT TESTING OF THE COMPLETE DELIVERY (in process testing) 3.6.1 When pulling the grounded dry cable through the test electrodes connected to the test voltage, there mus
17、t be no punctures. The test electrodes may consist of a coil, a metal tube, metal ball chains or any other type of suitable electrode. 3.6.2 Test Voltage for wires 0.5 mm2 5 kVeff The power supply shall be a transformer delivering a sinusoidal voltage. The electrode length and the frequency of the A
18、C voltage shall be chosen, considering the speed of cable running through the field of the electrode, so that each point of the cable shall be loaded by at least nine voltage cycles. If in place of a sinusoidal voltage unidirectional pulses are applied, there must be 18 pulses on each point of the c
19、able. 3.7 DURATION TEST VOLTAGE AND BREAKDOWN VOLTAGE (FLTM BB 101-12. The cable must not be punctured.) 3.7.1 Specimen Length 1.2 m 3.8 INSULATION RESISTIVITY (FLTM BB 101-13) 3.8.1 Specimen Length 5 m 3.8.2 Volume Resistivity, min 2 megaohm/m 3.9 INSULATION COMPRESSION TEST AT HIGH TEMPERATURE (FL
20、TM BB 101-14) 3.9.1 Specimen Length 100 mm 3.9.2 Test Temperature, C 150 3.10 HEAT AGED (ISO 188/ASTM D 573, 3000 h) Specimens are to be pieces of insulation removed from finished cable. A1 A2/A3 3.10.1 Test Temperature, C 150 135 3.10.2 Tensile Strength, min 11 MPa 3.10.3 Elongation, min 125% ENGIN
21、EERING MATERIAL SPECIFICATIONWSK-M1L126-A1/A2/A3Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 4 of 9 3.11 HEAT AGED (ISO 188/ASTM D 573, 48 h) Specimens are to be pieces of insulation removed from finished cable. A1 A2/A3 3.11.1 Test Temperature, C 180 160 3.11.
22、2 Tensile Strength, min 11 MPa 3.11.3 Elongation 125% 3.12 HEAT SHRINKAGE (FLTM BB 101-15) 3.12.1 Specimen Length 200 mm 3.12.2 Insulation Shrinkage, max 4% 3.13 RESISTANCE TO FLAME PROPAGATION (FLTM BB 101-16, Method B) 3.13.1 Specimen Length 0.5 m 3.13.2 Burn rate, max 100 mm/minute 3.13.3 Extingu
23、ishing Time 30 s 3.14 FLEXIBILITY AT LOW TEMPERATURE 3.14.1 Wire Size less than 10 mm2(FLTM BB 101-17,Method A) 3.14.1.1 Specimen Length 1.2 m 3.14.1.2 The insulation must not show puncture, crack or break. The conductor must not protrude from the insulation sheath and not be pushed out. 3.14.1.3 Pe
24、rform Voltage Breakdown Test (Perform per Para 3.7) 3.15 RETENTION OF CORE (FLTM BB 101-18) 3.15.1 Specimen Length 150 +/- 5 mm Applicable to cables up to and including 6.0 mm2. 3.16 OIL RESISTANCE (FLTM BB 101-19, Method A) 3.16.1 Specimen Length 1.2 m 3.16.2 Insulation Thickness Change, max +/- 4%
25、 ENGINEERING MATERIAL SPECIFICATIONWSK-M1L126-A1/A2/A3Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 5 of 9 3.16.3 Perform Voltage Breakdown Test (Perform per Para 3.7) 3.17 FUEL RESISTANCE (FLTM BB 101-19, Method B and C) 3.17.1 Specimen Length 1.2 m 3.17.2 Insu
26、lation Thickness Change, max +/- 8% 3.17.3 Perform Voltage Breakdown Test (Perform per Para 3.7) 3.18 ABRASION RESISTANCE (FLTM BB 101-20) 3.18.1 Specimen Length 750 mm 3.19 FOGGING, INTERIOR GLASS SURFACE (FLTM BO 116-03 or IEC 540 Para 7, 7 d at 100 +/- 2 C) FLTM BO 116-03: Fog Number, min 60 IEC
27、540 Para 7: Loss of Mass, max 1 mg/cm2Formation of excessive amount of clear film or droplets is cause for rejection. Note: Anti-Fogging is required for all wiring passing through the body shell luggage or passenger compartments. Wiring used exclusively in the engine compartment is excluded. ENGINEE
28、RING MATERIAL SPECIFICATIONWSK-M1L126-A1/A2/A3Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 6 of 9 Table 1a CABLE CONSTRUCTION WSK-M1L126-A1/A2 Wire Minimum Maximum Min Max Maximum Size Conductor Conductor Strand Resistance Lay Area Area Count per Unit Length Le
29、ngth (mm2) (mm2) (mm2) (milliohms/m) (mm) 0.35 0.329 0.350 7, 12 48.9 52.0 25 0.5 0.461 0.490 19 34.9 37.1 45 0.75 0.692 0.737 19, 24 23.2 24.7 45 1.0 0.925 0.982 32, 37 17.4 18.5 45 1.5 1.345 1.436 19, 37 11.9 12.7 45 2.5 2.25 2.39 37, 50 7.14 7.60 60 4.0 3.64 3.87 /= 56 4.42 4.70 65 6.0 5.52 5.87
30、/= 84 2.91 3.10 85 10.0 9.40 10.00 /= 75 1.71 1.82 110 16.0 14.74 15.68 /= 120 1.09 1.16 1.35 ENGINEERING MATERIAL SPECIFICATIONWSK-M1L126-A1/A2/A3Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 7 of 9 Table 1b CABLE CONSTRUCTION WSK-M1L126-A3 Wire Minimum Maximum
31、 Min Max Maximum Size Conductor Conductor Strand Resistance Lay Area Area Count per Unit Length Length (mm2) (mm2) (mm2) (milliohms/m) (mm) 0.35 0.329 0.350 7, 12 51.2 54.5 25 0.5 0.461 0.490 19 35.9 38.2 45 0.75 0.692 0.737 19, 24 23.9 25.4 45 1.0 0.925 0.982 32, 37 18.0 19.1 45 1.5 1.345 1.436 19,
32、 37 12.2 13.0 45 2.5 2.25 2.39 37, 50 7.33 7.80 60 4.0 3.64 3.87 /= 56 4.51 4.80 65 6.0 5.52 5.87 /= 84 3.01 3.20 85 10.0 9.40 10.00 /= 75 1.75 1.87 110 16.0 14.74 15.68 /= 120 1.11 1.18 1.35 ENGINEERING MATERIAL SPECIFICATIONWSK-M1L126-A1/A2/A3Printed copies are uncontrolled Copyright 2003, Ford Gl
33、obal Technologies, Inc. Page 8 of 9 Table 2 INSULATION CONSTRUCTION Wire Minimum Maximum Minimum Maximum Approximate Size Thickness of Diameter of Overall Overall Weight Per Insulation Conductor Diameter Diameter Unit Length (mm2) (mm) (mm) (mm) (mm) (kg/km) 0.35 0.20 0.9 1.2 1.4 4.5 0.5 0.22 1.0 1.
34、4 1.6 6 0.75 0.24 1.2 1.7 1.9 9 1.0 0.24 1.35 1.9 2.1 11 1.5 0.24 1.7 2.2 2.4 16 2.5 0.28 2.2 2.7 3.0 25 4.0 0.32 2.75 3.4 3.7 40 6.0 0.32 3.3 4.0 4.3 61 10.0 0.48 4.5 5.5 6.0 104 16.0 0.48 6.0 7.0 7.5 165 ENGINEERING MATERIAL SPECIFICATIONWSK-M1L126-A1/A2/A3Printed copies are uncontrolled Copyright
35、 2003, Ford Global Technologies, Inc. Page 9 of 9 TABLE 3 Munsell Color Coding System Color Low Concentrate High Concentrate Black N2.25 - Blue 4.6PB 3.8/10.2 5.6PB 2.75/9.4 Brown 5YR 6.25/4.0 5YR 5.5/4.6 Gray N6.3/(10GY,0.2) N5.2/(10GY,0.2) Green 0.5G 6.25/6.3 0.5G 5.1/7.5 Orange 8.75R 6.0/11.5 8.75R 5.5-13.5 Red 2.5R 4.1/11.2 4.4R 3.4/10.4 Violet 4.4P 3.9/6.7 3.4P 2.8/6.7 White - 5Y 9/1 Yellow 8.4Y 8.5/8.3 8Y 8.5/11.2 TABLE 4 DIN 47002 OR IEC 304 Color RAL Black 9005 Blue 5015 Brown 8003 Gray 7000 Green 6018 Orange 2003 Red 3000 Violet 4005 White 1013 Yellow 1021
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