1、 FORD LABORATORY TEST METHOD BB 101-11 Date Action Revisions 2000 08 30 Revised Editorial no technical change A. Cockman 2000 05 22 Editorial no technical change A. Cockman 1996 10 22 Printed copies are uncontrolled Page 1 of 16 Copyright 2000, Ford Global Technologies, Inc. PHYSICAL, ELECTRICAL, HE
2、AT AND COLD TESTING OF AUTOMOTIVE CABLE Application This procedure describes the method for performing the following tests on automotive insulated cable: I Electrical Resistance II Capacitance III Tensile Strength IV Re sistance to Heat V High Potential Breakdown VI Resistance to Heat VII Resistance
3、 to Hot Oil VIII Accelerated Life Cycle IX Resistance to Cold Refer to the applicable Engineering Specification for variances in specified test conditions, and failu re criteria. In case of disagreement, the Engineering Specification value shall be used. Apparatus Required Wheatstone Bridge Leeds an
4、d Northrup, Number 5430 - AM or equivalent. Oven Mechanical convection, range to 260 C, VWR Catalog Number 52347 - 452 o r equivalent. Bridge General Radio Company, Type 1650 B Impedance or equivalent. Fixture - See Figure 2 Weights As required. 67 kg 4.5 kg 2.3 kg 1.4 kg FORD LABORATORY TEST METHOD
5、 BB 101-11 Page 2 of 16 Copyright 2000, Ford Global Technologies, Inc. Mandrel Fixture in Figure 3 for winding cable on mandrel. High Voltage Source 15,000 and 20,000 v olts (rms) a - c (50 - 60 Hz) variable transformer to operate source from 0 - 20 000 in 1000 volt steps. General Electric Catalog N
6、o. 153X355 - 9 or equivalent. Sleeve Bell and brass sleeve 161.3 - 166.4 mm long and 40.9 - 41.4 mm inside diameter. See Figure 4. Beaker 1500 mL Mandrel Bar 50.8 mm in diameter. See Figure 2. Bar 13 mm in diameter. See Figures 6, 9 and 10. Bar 25 mm in diameter. See Figures 3 and 11. Brass Tube 255
7、/253 mm outside diameter, 281.94/277.16 mm long and 1.17/0.079 mm wall thicknes s. See Figure 4. Oil Bath Bath size (approximately): 330 mm long, 200 mm wide, and 200 mm deep Heater and control to maintain oil temperature at 88 - 93 C. Agitator Mechanical agitator to maintain heat distribution in oi
8、l bath. Water Bath Minimum di mensions: 330 mm long, 200 mm wide, and 200 mm deep. Control and heater to maintain temperature at 47 - 50 C. Cold Box Temperature - 37 +/ - 1 C. Hot Plate VWR Catalog No. 33918 - 400 or equivalent. Fixture Tensile strength fixture. See Figure 2. Thermometers As require
9、d. Ranges from - 36 to 166 C. Fume Hood FORD LABORATORY TEST METHOD BB 101-11 Page 3 of 16 Copyright 2000, Ford Global Technologies, Inc. Materials Required Oil Grade SAE 30 lubricating oil. Fuel ASTM Reference Fuel B. CAUTION: Low flash point. Refer to Fire Control Bulletin No. 18. Tape ASTM D 2301
10、 electrical tape or equiv alent. Deionized or Distilled Water 10 ppm max dissolved solids (ASTM D 1888). Sodium Chloride NaCl; c.p. Solutions Required Saturated Salt Solutions Saturated solution of NaCl and deionized or distilled water. 5 % Salt Solution 5 % solution of NaCl (by weight) in deionized
11、 or distilled water. Conditioning and Test Conditions All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/ - 2 C and 50 +/ - 5 % relative humidity for not less than 24 h prior to t esting and tested under the same conditions unless otherwise specifie
12、d. I - ELECTRICAL RESISTANCE OF AUTOMOTIVE CABLE Application This procedure is to determine the electrical resistance of automotive cable with insulated jacket. Procedure 1. Place cable under a 2.3 kg tension. 2. While under tension, cut sample piece of cable 3073 mm. 3. Strip insulation 13 mm on ea
13、ch end of cable. 4. Place stripped ends beneath terminals of the Wheatstone Bridge. FORD LABORATORY TEST METHOD BB 101-11 Page 4 of 16 Copyright 2000, Ford Global Technologies, Inc. 5. Read resistance in ohms per foot at 20 +/ - 1 C. 6. Report resistance as required by Engineering Specifications. II
14、 - CAPACITANCE OF AUTOMOTIVE CABLE Application This procedure is to determine the capacitance of automotive cable with insulating jacket. Procedure 1. Cut a 1372 mm length of cable. 2. Coil wire into form to fit into a 1500 mL beaker as shown in Figure 1. 3. Drive a pin into one end 13 mm deep in ce
15、nter of core. 4. Dry sample in oven at a temperature of 78 - 82 C for 18 hours. 5. Cool sample to 23 +/ - 2 C for 30 minutes. 6. Place 500 mL of distilled water in beaker. 7. Place cable in beaker along with contact electrode. 8. Connect electrode and pin to bridge. 9. Measure the composite dielectr
16、ic constant of the insulating material in pico farads per foot at 1,000 Hz. III - TENSILE STRENGTH OF AUTOMOTIVE CABLE Application This procedure is to determine the tensile strength of insulated automotive cable by the dead weight method. Procedure 1. Cut a sample 1830 mm long. 2. Securely fasten o
17、ne end to fixed 50 mm bar . See Figure 2. 3. Fasten the other end to the bar with 68 kg weight. A minimum of 300 mm of cable must be free between the stationary fixture and the weight. 4. Allow weight to hang free after gently releasing at the cable end. FORD LABORATORY TEST METHOD BB 101-11 Page 5
18、of 16 Copyright 2000, Ford Global Technologies, Inc. 5. Allow the weight t o remain in suspension for one minute. 6. Observe the cable for rupture or separation. IV - CORONA RESISTANCE OF AUTOMOTIVE CABLE Application This procedure is to determine whether insulation of automobile cable will withstan
19、d Corona. Procedure 1. Cut a specimen from cable 1220 mm long. 2. Measure 340 mm from one end of the sample cable. 3. Tape this point 64 mm from the end of the brass tube mandrel and place the mandrel in the winding fixture. See Figure 3. 4. Place a 2.3 kg weight on the oth er end of the cable and a
20、llow the weight to be freely suspended. 5. Rotate the mandrel, against the force of the attached weight, to obtain five complete turns 19 mm apart. After completing the five turns. Secure cable to the mandrel with tape. 6. Place the mandrel with the wound cable in the metal sleeve. See Figure 4. 7.
21、Attach insulator to one end of the cable. 8. Attach 15,000 volt source to mandrel, metal sleeve and free end of cable. 9. Apply 15,000 volts to fixture for five hours. 10. Observe cable for any failure point in insulation. V - HIGH POTENTIAL RESISTANCE OF AUTOMOTIVE CABLE Application This procedure
22、is to determine the ability of automotive cable to carry high potential. Procedure 1. Cut a sample of the cable in a 460 mm len gth. 2. Strip insulation back 25 mm on each end. FORD LABORATORY TEST METHOD BB 101-11 Page 6 of 16 Copyright 2000, Ford Global Technologies, Inc. 3. Twist the bare conduct
23、or ends together to form a loop of the cable. 4. Suspend the cable loop in distilled water so that 13 mm of the cable ends are above the water level. 5. Heat the water (in which the cable is suspended) on hot plate at 82 88 C for four hours. 6. Prepare a 5 % solution by volume using NaCl in a 1500 m
24、L beaker. 7. Remove looped cable from distilled water and immerse in salt solution. 82.5 +/ - 0.6 mm of each end of the cable sho uld protrude above the solution level. 8. Allow cable to remain in salt solution for 30 minutes. 9. Connect one end of voltage source to cable and the other end to the so
25、lution. See Figure 5. 10. Apply voltage beginning at zero, increasing at the rate of one kilo volt per five seconds to 20,000 volts. Hold at 20,000 volts for 5 minutes. 11. Observe for burning over the end or rupture of insulation. VI - RESISTANCE TO HEAT OF AUTOMOTIVE CABLE Application This procedu
26、re is to determine the resistan ce to heat of automotive cable with an insulated jacket. Procedure 1. Cut a section of cable 760 mm long. 2. Place the sample cable in an oven at 160 - 165 C for 72 hours. 3. Cool to 23 +/ - 2 C, then tape one end of cable to a 13 mm mandrel. 4. Att ach a 4.5 kg weigh
27、t to the opposite end and allow to hang freely. 5. Wind five complete turns in five seconds around mandrel. See Figure 4. 6. Remove the cable from mandrel and form into a coil not less than 75 mm in diameter. 7. Prepare a saturated sol ution of salt (approximately 500 g/L) and place in 1500 mL beake
28、r. 8. Immerse the cable in salt solution as shown in Figure 7. 9. Apply a potential difference of 15,000 volts between cable ends and salt solution for five minutes. 10. If no failure in in sulation is noted, increase voltage to 20,000 volts. 11. Allow 20,000 volts to remain applied for five minutes
29、 and then observe insulation for failure. FORD LABORATORY TEST METHOD BB 101-11 Page 7 of 16 Copyright 2000, Ford Global Technologies, Inc. VII - RESISTANCE TO HOT OIL OF AUTOMOTIVE CABLE Application This procedure is to determine the res istance to hot oil of automotive cable with an insulated jack
30、et. Procedure 1. Cut a 1220 mm specimen of the cable. 2. Secure one end of the cable 340 mm from end using tape to clean, polished brass tube mandrel. 3. Attach 2.3 kg weight to the other en d of the cable and suspend weight freely. 4. Rotate the mandrel against the force of the attached weight to o
31、btain five complete turns spaced 19 mm apart. See Figure 3. 5. Immerse the assembly in the oil tank, making sure the cable or mandrel does not t ouch bottom or sides of tank. Allow not less than 76 mm of the cable to protrude above the surface of the oil. 6. Start mechanical agitator in the oil main
32、tained at 88 - 93 C. 7. Allow assembly to remain in oil at temperature for 40 hours. See Figure 8. 8. Remove cable from oil bath and cool for 30 minutes. 9. Place mandrel and cable in bell end sleeve. See Figure 4. 10. Apply 15,000 volts (50 - 60 Hz) between cable end, mandrel, and sleeve for two ho
33、urs. See Figure 4. 11. Remove specimen from ma ndrel. 12. Tape end of cable 50 mm from end onto 13 mm mandrel. Place 2.3 kg weighton the other end and suspend weight freely. 13. Wind entire cable onto mandrel with coils touching. Wind in the opposite direction as the cable was wound on the original
34、25.4 mm mandrel. See Figure 9. 14. Observe insulation for cracking. VIII - ACCELERATED LIFE CYCLE TEST FOR AUTOMOTIVE CABLE Application This procedure describes a series of physical, hot, cold and electrical tests cycled to perform a life test on i nsulated automotive cable. FORD LABORATORY TEST MET
35、HOD BB 101-11 Page 8 of 16 Copyright 2000, Ford Global Technologies, Inc. Procedure 1. Cut a 1220 mm specimen of cable from wire to be tested. 2. Tape cable to brass tube mandrel 340 mm from the end of the cable. 3. Attach a 4.5 kg weight to the other end of cable and suspend freely. See Figure 10.
36、4. Wind cable on mandrel with coils touching. 5. Unwind and repeat winding opposite direction for the entire length of cable. 6. Unwind cable and tape 340 mm from end to a 25.4 mm mandrel. 7. Repeat Steps 3 through 6 on the same cable specimen. 8. Attach a 2.3 kg weight to the other end. See Figure
37、3. 9. Wind five turns with coils 19 mm apart. 10. Place the wound specimen and mandrel in the bell shaped sleeve. See Figure 4. 11. Conduct the following uninterrupted series of tests: A. First day : (1) Heat assembly in oven for five hours at 160 - 165 C. (2) Remove assembly from oven and immediate
38、ly immerse in water bath at 47 - 50 C for 18 hours. Allow 75 mm of each end of the cable to protrude above the surface of the water. (3) Remove assembly from water and drain for thirty minutes. (4) Subject assembly to 15,000 volts (50 - 60 Hz) for thirty minutes. See Figure 4. B. Second day: (1) Pla
39、ce assembly in oven at 160 - 165 C for five hours. (2) Remove the assembly from oven and immediately im merse in SAE 30 oil at 88 - 93 C for 18 hours. Allow 75 mm of each end of the cable to protrude above surface of oil. Remove assembly from oil and allow to drain for thirty minutes. (3) Connect th
40、e high voltage source to ends of cable as shown in Figur e 4. Apply 15,000 volts (50 - 60 Hz) to the assembly for thirty minutes. FORD LABORATORY TEST METHOD BB 101-11 Page 9 of 16 Copyright 2000, Ford Global Technologies, Inc. C. Third day: (1) Heat assembly in an oven at 160 - 165 C for five hours
41、. (2) Remove assembly from oven and cool in air for thirty minutes. (3) Immerse assembly in ASTM D 471 R eference Fuel B at 23 +/ - 3 C for 18 hours. Allow 75 mm of each end of the cable to protrude above surface of liquid. Caution: Fuel has low flash point. A fume hood is required to exhaust vapors
42、 of the fuel. (4) Remove assembly from the fuel and drai n for four hours. (5) Connect the high voltage source to ends of the cable as shown in Figure 4. Apply 15,000 volts (50 - 60 Hz) to the assembly for two hours. Observe cable insulation for failure. IX - RESISTANCE TO COLD TEST FOR AUTOMOTIVE C
43、ABLE Application This procedure is to determine the resistance to cold of automotive cable with an insulated jacket. Procedure 1. Cut a specimen of cable 600 mm in length. 2. Tape one end to the 25 mm mandrel 50 mm from the cable end. 3. Attach the 1.4 kg weight to the other end of the cable. 4. Pla
44、ce assembly in a cold box at - 40 +/ - 1 C and allow weight to hang freely. 5. After two hours, wind the specimen on the mandrel for five complete turns (one turn per five seconds) while leaving assembly in col d box. 6. Examine insulation of cable for cracking. Chemicals, materials, parts, and equi
45、pment referenced in this document must be used and handled properly. Each party is responsible for determining proper use and handling in its facilities. FORD LABORATORY TEST METHOD BB 101-11 Page 10 of 16 Copyright 2000, Ford Global Technologies, Inc. PHYSICAL, ELECTRICAL, HEAT AND COLD TESTING OF
46、AUTOMOTIVE CABLE Figure 1 Figure 2 FORD LABORATORY TEST METHOD BB 101-11 Page 11 of 16 Copyright 2000, Ford Global Technologies, Inc. PHYSICAL, ELECTRICAL, HEAT AND COLD TESTING OF AUTOMOTIVE CABLE Figure 3 FORD LABORATORY TEST METHOD BB 101-11 Page 12 of 16 Copyright 2000, Ford Global Technologies,
47、 Inc. PHYSICAL, ELECTRICAL, HEAT AND COLD TESTING OF AUTOMOTIVE CABLE Figure 4 FORD LABORATORY TEST METHOD BB 101-11 Page 13 of 16 Copyright 2000, Ford Global Technologies, Inc. PHYSICAL, ELECTRICAL, HEAT AND COLD TESTING OF AUTOMOTIVE CABLE Figure 5 All dimensions in mm Figure 6 All dimensions in m
48、m FORD LABORATORY TEST METHOD BB 101-11 Page 14 of 16 Copyright 2000, Ford Global Technologies, Inc. PHYSICAL, ELECTRICAL, HEAT AND COLD TESTING OF AUTOMOTIVE CABLE Figure 7 All dimensions in mm Figure 8 All dimensions in mm FORD LABORATORY TEST METHOD BB 101-11 Page 15 of 16 Copyright 2000, Ford Gl
49、obal Technologies, Inc. PHYSICAL, ELECTRICAL, HEAT AND COLD TESTING OF AUTOMOTIVE CABLE Figure 9 All dimensions in mm Figure 10 All dimensions in mm FORD LABORATORY TEST METHOD BB 101-11 Page 16 of 16 Copyright 2000, Ford Global Technologies, Inc. PHYSICAL, ELECTRICAL, HEAT AND COLD TESTING OF AUTOMOTIVE CABLE Figure 11 All dimensions i n mm Figure 12
