1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 06 23 Revised Para 3.0 inserted; Para 3.1, 3.2, 3.3, 3.11, 3.12, 4 deleted 1994 02 25 NB00I10043054315 Released J. Showalter Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 1 of 5 CABLE, LOW TENSION, PO
2、LYURETHANE INSULATED, 80 C, WSB-M1L132-A1 HEAVY WALL, COILED AND FLEXIBLE 1. SCOPE The material defined by this specification is a low tension stranded, heavy wall, polyurethane insulated cable. It is a coiled flexible cable capable of withstanding 80 C. 2. APPLICATION This specification was release
3、d originally for a cable used to supply electrical power to accessories mounted on the lift gate (such as the rear window wiper motor). Note: The assemblers of electrical wire harnesses shall use the bulk wire suppliers as shown in the Ford Motor Company Approved Source List. 3. REQUIREMENTS 3.0 STA
4、NDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.4 CONSTRUCTION 3.4.1 Conductor (See Table 1) Conductor Diameter: The diameter of individual strands and finished conductor
5、 may be measured using a machinist micrometer, laser micrometer or other suitable measuring instruments readable to at least 0.01 mm. Circular Mil Area: Take a section of uninsulated conductor and measure the individual strand diameters using a machinist micrometer, laser micrometer or other suitabl
6、e measuring instruments readable to at least 0.01 mm. Calculate the average strand diameter, then determine the cross sectional circular mil area by squaring the diameter of strands in mils and then multiplying by the number of strands. Conductor Stranding: Unless otherwise specified, the individual
7、 strands of the conductor shall be soft or annealed copper conforming to ASTM B 3. The conductor shall be rope lay stranded copper having bunched members employing 36 AWG single end wire similar to arrangements found in ASTM B 172. The maximum lay lengths shall be as specified in ASTM B 172. (Note:
8、ASTM B 172 does not define a class for the 36 AWG single end rope lay stranded wire as called out in this specification). ENGINEERING MATERIAL SPECIFICATIONWSB-M1L132-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 5 3.4.2 Insulation Wall Thickness (See Tab
9、le 1) Strip approximately 2.5 cm of insulation from the finished wire and make a 90 degree crosscut using a sharp razor blade. Using a Federal pin Gage, Shadow graph or equivalent optical measuring device, locate and measure the minimum and maximum insulation wall thickness. The average of the minim
10、um and maximum readings shall meet the values specified in Table 1. Note: Individual readings must not be less than the values specified in Table 1. 3.4.3 Cable Diameter (See Table 1) Take a suitable length of wire and measure the diameter of the cable using a machinist micrometer, laser micrometer
11、or equivalent. Check the diameter in four places rotating the wire 90 deg and record the average value of the four readings. 3.5 JOINTS Bunched strands at the joint must meet 80.0% of its original tensile strength. Note: Tensile strength and machine capability defined by SPC standard recommendation
12、must be established prior to making joints for production. Take a 300 mm sample of bunched conductor and place it in the jaws of a tensile pulling machine or equivalent. Set the jaw separation at 250 mm. Pull the tensile sample at a rate of 50 mm per minute. Record the maximum value obtained. Next,
13、repeat the test using a tensile sample containing a joint. Note: When checking the tensile strength of the joint, the joint must be centered between the jaws of the tensile machine. 3.6 COLOR TOLERANCE (See Table 2) The Munsell Color Tolerance set has the desired color in the center, surrounded by c
14、olors that deviate from it by small amounts in various directions in color space. Ideally, the base, secondary or printing color being inspected should match the central color. It must not deviate from the central color be more than the specified color limits. Comparison must be made by a person wit
15、h normal or corrected vision, under a Pantone Viewing light or equivalent using daylight conditions. The surface being inspected and the tolerance set must be in the same plane. Cable samples must be placed flat, overlapping the color standard. Either of the illuminating and viewing arrangements sho
16、wn below are acceptable. ENGINEERING MATERIAL SPECIFICATIONWSB-M1L132-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 3 of 5 3.7 STRIPABILITY 12 gauge - TBD Take a 125 mm piece of wire and remove 75 mm of insulation from one end only. Place the sample into the f
17、ixture (Figure 1 or equivalent) so that the insulated portion is behind the key slot, then pull the sample at a rate of 500 mm per minute. Record the highest value obtained. Note: No insulation residue shall be allowed on the conductor. 3.8 SPARK TESTER (UL Test Method 1581, Section 900) All Wall Th
18、icknesses 3,000 volts All wire must go through spark tester during extrusion processes and all spark outs must be removed. 3.9 COIL (See Drawing Number SA-0189-4C) Using a machinist micrometer or equivalent measure the overall length, diameter and coil length of the circuit. Product Validation (Annu
19、al Certification) 3.10 CABLE QUALITY TESTS Dielectric Test, Cold Bend Test, Flame Test and Pinch Test correspond respectively to sections 4.3, 4.4, 4.5 and 4.9 of SAE J1128. Results of these tests shall comply with the requirements of SAE J1128 type HDT. The test listed below shall be conducted in a
20、ddition to the test listed above: Insulation Physical Property Test: Shall be conducted in accordance to section 4.2, SAE J1128 for type HDT except the initial physical properties shall be as follows: Tensile, min 13.8 MPa Elongation, min 300% Coil Retract ability Test Coil dimension - Distance betw
21、een coils shall not increase by more than 6.3 mm Take a circuit as described in drawing number SA-0189-4 and place the circuit vertically in air circulating oven securing one end to the oven rack and attach a 227 g weight to the opposite end. Raise the oven temperature to 60 +/- 2 C and maintain thi
22、s temperature for a period of 2.0 h. Next, remove the weight from the circuit and place the circuit on a flat table at 23 +/- 2 C for a period of 2.0 h to allow the circuit to stabilize. Measure the distance of the coils using a machinist micrometer, caliper or equivalent. ENGINEERING MATERIAL SPECI
23、FICATIONWSB-M1L132-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 4 of 5 5. GENERAL INFORMATION The information below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 Color Charts are available from: SAE Custom
24、er Service/Publication 400 Commonwealth Drive Warrendale, PA 15096 (412) 776-4841 ENGINEERING MATERIAL SPECIFICATIONWSB-M1L132-A1Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 5 of 5 TABLE 1 CONDUCTOR DIMENSIONS Wire Size Conductor Stranding (A) Nom. Cond. Dia. (
25、A) CMA SAE Strand No. Nom. Size min max 12 7 x 37 0.0050“ 0.104“ 6219 6737 (0.127 mm) (2.642 mm) INSULATION DIMENSIONS Wire Size Insulation Thickness Finished Cable Diameter min max min max 12 0.035“ 0.045“ 0.180“ 0.190“ (0.889 mm) (1.143 mm) (4.572 mm) (4.826 mm) (A) Neither the nominal strand diam
26、eter nor nominal conductor diameter are intended for checking purposes. However, the individual strands must not vary from nominal by more than plus or minus 0.0001“ (0.00254 mm). TABLE 2 Color Light Central Dark Red 2.5R 4.2/11.2 3.3R 3.8/11.0 4.4R 3.4/10.4 Orange 8.75R 6.0/11.5 8.75R 5.75/12.5 8.7
27、5R 5.5/13. Brown 10R 3.51/1.0 0.8YR 3.0/1.0 4.6YR 2.5/1.0 Tan 5YR 6.25/4.0 5YR 5.9/4.3 5YR 5.5/4.6 Yellow 8.4Y 8.5/8.3 8.2Y 8.5/9.8 8Y 8.5/11.2 Lt. Green 0.5G 6.25/6.3 0.5G 5.6/7.0 0.5G 5.1/7.5 Dk. Green 2.2BG 4.75/9.4 1.3BG 4.25/9.4 0.5BG 3.75/9. Lt. Blue 9B 5.4/5.0 9B 5.0/5.0 9B 4.7/5.0 Dk. Blue 4.6PB 3.8/10.2 5.2PB 3.3/9.8 5.6PB 2.75/9. Purple 4.4P 3.9/6.7 3.9P 3.4/6.7 3.4P 2.8/6.7 Pink 7RP 6.1/11.5 7.2RP 5.6/12.1 7.7RP 5.2/12. Gray N6.3/(10GY,0.2) N5.7/(10GY,0.2) N5.2/(10GY,0. White - 5Y 9/1 5Y 8.5/1 Black N4 N 2.25 -
