1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 08 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 1992 04 28 EE00E10206442000 Released MD/FE-12 P. Rade Printed copies are uncontrolled Copyright 2003, F
2、ord Global Technologies, Inc. Page 1 of 8 CABLE, LOW TENSION, TPE INSULATED, 150 C, WSK-M1L131-A1 THIN WALL, SHIELDED, BARE, TRIPLE CORE CABLE, LOW TENSION, TPE INSULATED, 135 C, WSK-M1L131-A2 THIN WALL, SHIELDED, BARE, TRIPLE CORE CABLE, LOW TENSION, TPE INSULATED, 135 C, WSK-M1L131-A3 THIN WALL, S
3、HIELDED, TINNED, TRIPLE 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 thickness. It is a spirally wound shielded wire with a 90% shield cover
4、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 suppliers as shown in the Ford Motor Company Approved Source List. 3. REQUIREMENTS 3
5、.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 1.2 m 3.3.2 The maximum outside diameter shall be determined by taking measurements at
6、 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. 3.4 CONDUCTOR 3.4.1 The conductor of all cable classes shall consist of bunched or stran
7、ded soft annealed copper wire. 3.4.2 Specimen Length 1.2 m 3.4.3 Three sections 10 mm long and separated by at least 400 mm shall be cut from the specimen. Carefully remove the conductor without deformation of the insulation. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L131-A1/A2/A3Printed copies are un
8、controlled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 8 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 diameter at each point. The measurements shall
9、 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 of the individual strand areas. As an alternate
10、 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 conductor diameter. Minimum number of wires shall comp
11、ly 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 d 0.287 mm e 20% Where: d = individual strand d
12、iameter 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 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 smoo
13、th 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 shall 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 an
14、d the tolerance set must be the same plane. Cable samples must be placed flat, overlapping the color standard. 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
15、 conform to Table 4. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L131-A1/A2/A3Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 3 of 8 3.5.3 The minimum insulation thickness shall be determined by taking measurements at three points separated by at least 100 mm and reco
16、rding 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= INSULATION TPE 3= SHIELDING
17、SPIRALLY WOUND SHIELD, COPPER 90% SHIELD COVER, HELIX ANGLE 10 DEGREE 4= SHEATHING TPE (BLACK) 3.7 FAULT TESTING OF THE COMPLETE DELIVERY (in process 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 ele
18、ctrodes 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 mm25 kVeff 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 th
19、e 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 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
20、 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 Length 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 ENGINEERING MATERIAL SPECIFICATIONWS
21、K-M1L131-A1/A2/A3Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 4 of 8 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 3.11 HEAT AGED (ISO 188/ASTM D 573, 3000 h) Specimens are to
22、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 AGED (ISO 188/ASTM D 573, 48 h) Specimens are to be pieces of insulation removed from finished cable. 3.12.1 Test Temperature, C
23、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 Shrinkage, 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/min
24、ute 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 ENGINEERING MATERIAL SPECIFICATIONWSK-M1L131-A1/A2/A3Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page
25、5 of 8 3.15.1.2 The insulation must not show puncture, crack or break. The conductor must not protrude from the insulation sheath and not be pushed out. 3.15.1.3 Perform Voltage Breakdown Test (Perform per para 3.7) 3.16 RETENTION OF CORE (FLTM BB 101-18) 3.16.1 Specimen Length 150 +/- 5 mm Applicab
26、le 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 Breakdown Test (Perform per para 3.7) 3.18 FUEL RESISTANCE (FLTM BB 101-19, Method B and C) 3.18.1 Specimen Leng
27、th 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 FOGGING, INTERIOR GLASS SURFACE (FLTM BO 116-03 or IEC 540 Para 7, 7 d at 100 +/- 2 C) FLTM BO 116-03: Fog
28、 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 through the body shell luggage or passenger compartments. Wiring used exclusively in the engine compartme
29、nt is excluded. ENGINEERING MATERIAL SPECIFICATIONWSK-M1L131-A1/A2/A3Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 6 of 8 Table 1a CABLE CONSTRUCTION WSK-M1L131-A1/A2 Wire Minimum Maximum Min Max Maximum Size Conductor Conductor Strand Resistance Lay Area Area C
30、ount per Unit 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 7.60 60 Table 1b CABLE CONSTRUCTION WSK-M1L131-A3 Wire Minimum Maxim
31、um Maximum Maximum Size Conductor Conductor Strand Resistance Lay Area Area Count per Unit 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 19.1 45 1.5 1.345 1.436 30, 37 12.2 13.0 45 2.5 2.25 2.39 37,
32、 50 7.33 7.80 60 ENGINEERING MATERIAL SPECIFICATIONWSK-M1L131-A1/A2/A3Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 7 of 8 Table 2 INSULATION CONSTRUCTION Single Wire Wire Minimum Maximum Minimum Maximum Approximate Size Thickness Diameter Overall Overall Weight
33、 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 Cable Sleeve Wall Shield No.
34、 of Diameter Thickness Wires & Diameter Guide Value (mm2) (mm) (mm) (mm) 0.5 5.2 + 0 - 0.4 0.6 44 x 0.20 0.75 5.7 + 0 - 0.4 0.6 50 x 0.20 1.0 6.2 + 0 - 0.4 0.6 56 x 0.20 1.5 6.8 + 0 - 0.5 0.6 64 x 0.20 2.5 8.5 + 0 - 0.5 0.7 52 x 0.30 ENGINEERING MATERIAL SPECIFICATIONWSK-M1L131-A1/A2/A3Printed copie
35、s are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 8 of 8 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
36、.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
