1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2003 04 25 Revised Para 3.0 inserted; Para 3.6, 3.7, 3.8, 3.9, 3.10, 4 deleted 1993 08 13 NB00I10043054278 Released J.M. Showalter Printed copies are uncontrolled Page 1 of 4 Copyright 2003, Ford Global Tech
2、nologies, Inc. CABLE, LOW TENSION, VINYL INSULATED, STRANDED, FLEXIBLE ESB-M1L77-A2 1. SCOPE The material defined by this specification is a stranded vinyl covered allow tension flexible cable. The vinyl covering shall have a maximum service temperature of 85 C. 2. APPLICATION This specification was
3、 released originally for material used for automotive electrical wiring. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1 COLOR The color of the v
4、inyl insulation shall be specified on the engineering drawing of the component utilizing this material. Base and stripe color codes shall correspond to SAE J1128. Where striping is specified, the stripe shall be a minimum of 0.5 mm wide, but not more than 19% of the circumference of the wire. The st
5、ripe shall be of the same material as the vinyl insulation. 3.2 CABLE CONSTRUCTION See Table I 3.3 WIRE QUALITY The strands of the conductors prior to stranding shall consist of ESF-M2L1-A, soft or annealed bare copper wire. ENGINEERING MATERIAL SPECIFICATION ESB-M1L77-A2 Page 2 of 4 Copyright 2003,
6、 Ford Global Technologies, Inc. 3.4 INSULATION QUALITY Shall be a good grade vinyl chloride copolymer which will pass the following test requirements: The material shall adhere closely to, but strip readily from the conductors, leaving them reasonably clean and in suitable condition for soldering. 3
7、.4.1 Mechanical Properties (ASTM D 412, Die “A“, 305 mmminute test speed) Standard laboratory test slabs shall be prepared by compression molding the thermoplastic material of the same composition and grade as used for the wire insulation. Tensile Strength, min 13.1 MPa Elongation, min 125% 3.4.2 Di
8、electric Test A specimen of the cable 610 mm long shall be formed into a loop. One 25 mm strip of the insulation shall be removed from each end of the wire and the ends twisted together. The loop thus formed shall be immersed in water containing 5% salt by weight at 23 +/- 2 C, so that no more than
9、152 mm of each end of the specimen protrudes above the solution. After being immersed for 5 h, and while still immersed, the specimen shall withstand the application of 1000 volts (rms) at 60 Hz frequency, between the conductor and the water for 1 minute without rupture of the insulation. 3.4.3 High
10、 Temperature Resistance One 25 mm strip of the insulation shall be removed from each end of a 610 mm sample of the finished cable. The sample shall be then suspended around a cylindrical mandrel having a diameter of 165 mm. Each end of the conductor shall have suspend from it a weight of 0.45 kg. Th
11、is condition shall be maintained for 120 h in a mechanical convection oven at 120 +/- 2 C. When cool, the weight shall be removed from the specimen and it shall be taken off the mandrel, bent in the reverse direction around a mandrel of 152 mm diameter at a rate not to exceed one complete turn/minut
12、e and then be subjected to the dielectric test, para 3.4.2. 3.4.4 Oil Resistance A specimen 610 mm long shall be immersed to within 38 mm from the ends in a mixture of equal parts of kerosene and engine lubricating oil at a temperature of 50 +/- 2 C for a period of 20 h. The sample shall then be rem
13、oved from the solution, examined for deterioration of the insulating compound, and gaged for swelling. ENGINEERING MATERIAL SPECIFICATION ESB-M1L77-A2 Page 3 of 4 Copyright 2003, Ford Global Technologies, Inc. The outside diameter of the cable insulation shall not increase more than 15%. The sample
14、shall then be bent around a mandrel 152 mm in diameter and checked for cracking. After the bend test the cable shall pass the dielectric test, para 3.4.2. 3.4.5 Cold Resistance A straight specimen shall be reduced to a temperature not to exceed 5 C/minute. After maintaining this temperature for 3 h
15、and while still at this low temperature, the cable shall be wrapped around a mandrel 152 mm in diameter for 180 at the uniform rate of one turn in 10 s. The insulation shall be removed for a distance of 25 mm from each end of the specimen and the specimen subjected to the dielectric test, para 3.4.2
16、. 3.4.6 Flame Test A 610 mm specimen shall be suspended in a vertical position within a partial enclosure which allows a flow of sufficient air flow of sufficient air for complete combustion but is free from drafts. The tip of a 50 mm gas flame with an inner cone one-third its height shall then be a
17、pplied to the end of the specimen for 15 s. After removal of the flame, the specimen shall not continue to burn form more than 30 s. 3.4.7 Abrasion Resistance, min As per Table II (SAE J 1128) 3.4.8 Thickness A short length of insulation shall be stripped from the cable, and a thin cross section sli
18、ced from it. Measure the wall thickness. Wall Thickness, min 0.356 mm Wall Thickness, max 0.711 mm 3.5 FOGGING (SAE J1756, 3 h at 100 C heating, 21 C cooling plate, post test conditioning 1 h and 16 h) Fog Number, min 60 Formation of clear film, droplets or crystals is cause for rejection. Note: Ant
19、i-fogging is required for all wiring passing through the body shell luggage or passenger compartments. Wiring used exclusively in the engine compartment is excluded. ENGINEERING MATERIAL SPECIFICATION ESB-M1L77-A2 Page 4 of 4 Copyright 2003, Ford Global Technologies, Inc. TABLE I CABLE CONSTRUCTION
20、SAE Wire Size No. of Wires Nominal Strand Size Minimum Dia. of Strand Area of Conductor Maximum Dia. of Finished Cable Awg mm mm2mm 20 41 36 0.124 0.497 2.03 18 65 36 0.124 0.790 2.29 16 65 34 0.157 1.226 2.67 14 65 32 0.196 1.951 3.18 TABLE II ABRASION RESISTANCE DATA Gage Size Minimum Resistance Length of Tape Weight Support Bracket Weight mm kg 20 305 A 0.45 18 305 A 0.45 16 305 A 0.45 14 152 B 1.36
