1、 ENGINEERING MATERIAL SPECIFICATION Material Name Specification Number Date Action Revisions 2003 06 13 Revised Para 3.0 inserted; Para 3.1, 3.2, 3.21, 4 deleted 1992 10 10 EE00E10176310000 Pages 1, 3, 9, & 10 Revised MD/FE-12 P. Rade 1991 10 31 EE00I01194000000 Released MD/FE-12 P. Rade Printed cop
2、ies are uncontrolled Page 1 of 9 Copyright 2003, Ford Global Technologies, Inc. CABLE, LOW TENSION, TPE INSULATED, 150 C, WSK-M1L128-A1 THIN WALL, SHIELDED AND TWISTED, BARE, TWO CORE CABLE, LOW TENSION, TPE INSULATED, 135 C, WSK-M1L128-A2 THIN WALL, SHIELDED AND TWISTED, BARE, TWO CORE CABLE, LOW T
3、ENSION, TPE INSULATED, 135 C, WSK-M1L128-A3 THIN WALL, SHIELDED AND TWISTED, TINNED, TWO CORE 1. SCOPE The material defined by these specifications is a low tension stranded cable, thermoplastic elastomer (TPE) insulated conductor. The cable is similar to ISO 6722 with a thin wall insulation thickne
4、ss. It is a spirally wound shielded and twisted wire with a 90% shield cover and a helix angle of 10%. 2. APPLICATION These specifications were released originally for materials used in automotive electrical harnesses. Note: The assemblers of electrical wire harnesses shall use the bulk wire supplie
5、rs 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 Materials (WSS-M99P1111-A). 3.3 CABLE 3.3.1 Specimen Length 1.2m 3.3.
6、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 exceed the maximum overall diameter as specified in Table 2. ENGINEERING
7、MATERIAL SPECIFICATION WSK-M1L128-A1/A2/A3 Page 2 of 9 Copyright 2003, Ford Global Technologies, Inc. 3.4 CONDUCTOR 3.4.1 The conductor of all cable classes shall consist of bunched or stranded soft annealed copper wire. 3.4.2 Specimen Length 1.2 m 3.4.3 Three sections 10 mm long and separated by at
8、 least 400 mm shall be cut from the specimen. Carefully remove the conductor without deformation of the insulation. 3.4.4 The conductor diameter shall be determined by measuring the inside diameter of the insulation taken at three points separated by at least 100 mm and recording the maximum inside
9、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. 3.4.5 The conductor area may be determined by measuring individual strand diameters and calculating the sums o
10、f 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. 3.4.6 The strands shall be bunched and the maximum lay length shall be a maximum of 50 times the conducto
11、r diameter. Minimum number of wires shall comply with Tables 1 and 2. Maximum variation between individual strand diameters must not exceed 10 % per the following: max strand dia - min strand dia Variation = _ min strand dia Missing strands are not allowed. 3.4.7 Elongation (ASTM B 3) For d 15% For
12、d 0.287 mm e 20% Where: d = individual strand diameter e = elongation of individual strand 3.4.8 Resistivity, max (ASTM B 193, at 20 C) Bare 1.7094 microohm/cm Tinned 1.7544 microohm/cm ENGINEERING MATERIAL SPECIFICATION WSK-M1L128-A1/A2/A3 Page 3 of 9 Copyright 2003, Ford Global Technologies, Inc.
13、3.5 INSULATION AND SHEATHING 3.5.1 The insulating 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. 3.5.2 The color of the cables are per the Munsell Color Coding System and sha
14、ll conform to Table 3. 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 the same plane. Cable samples must be placed flat, overlapping the color standard. Color tolerance Reference Se
15、ts 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. 3.5.3 The minimum insulation thickness shall be determined by taking measurements at three points separated by at leas
16、t 100 mm and recording the minimum insulation thickness at each point. The thickness shall be measured with an optical device accurate to at least 0.01 mm. No single value shall be lower than the minimum insulation thickness specified in Table 2. 3.6 CABLE CONSTRUCTION 1 = CONDUCTOR CU 2 = INSULATIO
17、N TPE 3 = SHIELDING SPIRALLY WOUND SHIELD, COPPER, 90% SHIELD COVER, HELIX ANGLE 10 DEGREE 4 = SHEATHING TPE (BLACK) ENGINEERING MATERIAL SPECIFICATION WSK-M1L128-A1/A2/A3 Page 4 of 9 Copyright 2003, Ford Global Technologies, Inc. LAY LENGTH = 45 mm 3.7 FAULT TESTING OF THE COMPLETE DELIVERY (in pro
18、cess testing) 3.7.1 When pulling the grounded dry cable through the test electrodes connected to the test voltage, there must be no punctures. The test electrodes may consist of a coil, a metal tube, metal ball chains or any other type of suitable electrode. 3.7.2 Test Voltage For wires 0.5 mm2 5 kV
19、eff For conductor against shield 1.5 kVeff for 1 minute The power supply shall be a transformer delivering a sinusoidal voltage. The electrode length and the frequency of the AC voltage shall be chosen, considering the speed of cable running through the field of the electrode, so that each point of
20、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 cable. 3.8 DURATION TEST VOLTAGE AND BREAKDOWN VOLTAGE (FLTM BB 101-12, the cable must not be punctured) 3.8.1 Specimen Lengt
21、h 1.2 m 3.9 INSULATION RESISTIVITY (FLTM BB 101-13) 3.9.1 Specimen Length 5 m 3.9.2 Volume Resistivity, min 2 megaohm/m 3.10 INSULATION COMPRESSION TEST AT HIGH TEMPERATURE (FLTM BB 101-14) 3.10.1 Specimen Length 100 mm 3.10.2 Test Temperature, C 150 ENGINEERING MATERIAL SPECIFICATION WSK-M1L128-A1/
22、A2/A3 Page 5 of 9 Copyright 2003, Ford Global Technologies, Inc. 3.11 HEAT AGED (ISO 188/ASTM D 573, 3000 h) Specimens are to be pieces of insulation removed from finished cable. A1 A2/A3 3.11.1 Test Temperature, C 150 135 3.11.2 Tensile Strength, min 11 MPa 3.11.3 Elongation, min 125% 3.12 HEAT AGE
23、D (ISO 188/ASTM D 573, 48 h) Specimens are to be pieces of insulation removed from finished cable. A1 A2/A3 3.12.1 Test Temperature, C 180 160 3.12.2 Tensile Strength, min 11 MPa 3.12.3 Elongation, min 125% 3.13 HEAT SHRINKAGE (FLTM BB 101-15) 3.13.1 Specimen Length 200 mm 3.13.2 Insulation Shrinkag
24、e, max 4% 3.14 RESISTANCE TO FLAME PROPAGATION (FLTM BB 101-16, Method B) 3.14.1 Specimen Length 0.5 m 3.14.2 Burn Rate, max 100 mm/minute 3.14.3 Extinguishing Time 30 s 3.15 FLEXIBILITY AT LOW TEMPERATURE 3.15.1 Wire Sizes Less Than 10 mm2(FLTM BB 101-17, Method A) 3.15.1.1 Specimen Length 1.2 m 3.
25、15.1.2 The insulation must not show puncture, crack or break. The conductor must not protrude from the insulation sheath and not be pushed out. ENGINEERING MATERIAL SPECIFICATION WSK-M1L128-A1/A2/A3 Page 6 of 9 Copyright 2003, Ford Global Technologies, Inc. 3.15.1.3 Perform Voltage Breakdown Test (P
26、erform per para 3.7) 3.16 RETENTION OF CORE (FLTM BB 101-18) 3.16.1 Specimen Length 150 +/- 5 mm Applicable to cables up to and including 6.0 mm2. 3.17 OIL RESISTANCE (FLTM BB 101-19, METHOD A) 3.17.1 Specimen Length 1.2 m 3.17.2 Insulation Thickness Change, max +/- 4% 3.17.3 Perform Voltage Breakdo
27、wn Test (Perform per para 3.7) 3.18 FUEL RESISTANCE (FLTM BB 101-19, Method B and C) 3.18.1 Specimen Length 1.2 m 3.18.2 Insulation Thickness Change, max +/- 8% 3.18.3 Perform Voltage Breakdown Test (Perform per para 3.7) 3.19 ABRASION RESISTANCE (FLTM BB 101-20) 3.19.1 Specimen Length 750 mm 3.20 F
28、OGGING, 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 540 Para 7: Loss of Mass, max 1 mg/cm2The formation of droplets or coalescence into a clear film is cause for rejection. Note: Anti-fogging is required for all wiring passing
29、through the body shell luggage or passenger compartments. Wiring used exclusively in the engine compartment is excluded. ENGINEERING MATERIAL SPECIFICATION WSK-M1L128-A1/A2/A3 Page 7 of 9 Copyright 2003, Ford Global Technologies, Inc. Table 1 CABLE CONSTRUCTION WSK-M1L128-A1/-A2 Wire Minimum Maximum
30、 Min Max Size Conductor Conductor Strand Resistance Area Area Count per Unit Lay Length Length (mm2) (mm2) (mm2) (milliohms/m) (mm) 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 30, 37 11.9 12.7 45 2.5 2.25 2.39 37, 50 7.14 7
31、.60 60 Table 1b CABLE CONSTRUCTION WSK-M1L128-A3 Wire Minimum Maximum Maximum Size Conductor Conductor Strand Resistance Area Area Count per Unit Lay Length Length (mm2) (mm2) (mm2) (milliohms/m) (mm) 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
32、.1 45 1.5 1.345 1.436 30, 37 12.2 13.0 45 2.5 2.25 2.39 37, 50 7.33 7.80 60 ENGINEERING MATERIAL SPECIFICATION WSK-M1L128-A1/A2/A3 Page 8 of 9 Copyright 2003, Ford Global Technologies, Inc. Table 2 INSULATION CONSTRUCTION Single Wire Wire Minimum Maximum Minimum Maximum Approximate Size Thickness Di
33、ameter Overall Overall Weight per of Insul. of Cond. Diameter Diameter Unit Length (mm2) (mm) (mm) (mm) (mm) (kg/km) 0.5 0.22 1.0 1.4 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 Wire Bundle Wire Maximum Nominal Insulating Spirally Wound Size
34、 Cable Sleeve Wall Shield No. of Diameter Thickness Wires & Diameter Guide Value (mm2) (mm) (mm) (mm) 0.5 5.0 + 0 - 0.4 0.6 38 x 0.20 0.75 5.4 + 0 - 0.4 0.6 42 x 0.20 1.0 5.8 + 0 - 0.4 0.6 46 x 0.20 1.5 6.4 + 0 - 0.4 0.6 54 x 0.20 2.5 8.0 + 0 - 0.5 0.7 44 x 0.30 ENGINEERING MATERIAL SPECIFICATION WS
35、K-M1L128-A1/A2/A3 Page 9 of 9 Copyright 2003, Ford Global Technologies, Inc. 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
