1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 06 25 Revised Para 3.0 inserted; para 3.1, 3.2, 3.6, 4 deleted 2001 06 07 Activated R. Patel Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 1 of 3 CABLE, PRIMARY LOW TENSION, POLYVINYL CHLORIDE WSS-M1L
2、120-A4 INSULATED, THIN WALL 1. SCOPE The material defined by this specification is a low tension stranded cable insulated with polyvinyl chloride (PVC). The cable is similar to SAE J1128, type TWP. 2. APPLICATION This specification was originally released for S197 and V229 automotive cable applicati
3、ons requiring the use of PVC insulation. 3. REQUIREMENTS Material specification requirements are to be used for initial qualification of materials. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Producti
4、on Materials (WSS-M99P1111-A). 3.3 CONDUCTOR (SAE J1128/ASTM B 1/ASTM B 193) 3.3.1 The conductors shall meet all requirements of SAE J1128 with wire size and stranding as shown in Table 1 of this specification. 3.3.2 Before Bunching The wire must meet the requirements of ASTM B 1 for tensile strengt
5、h, elongation, resistivity, dimensions and finish. 3.3.3 Conductor resistance shall be measured by stripping 30 mm of insulation from each end of a 1050 mm cable (use of a longer specimen is optional). Solder (optional) 25mm along each end of the specimen. Condition the specimen for a minimum of 4 h
6、ours at 23 C +/- 5 C. Measure the unsoldered length, the ambient temperature, and the resistance of the specimen. Calculate the resistance per meter. Calculate the resistance at 20 C using the temperature correction method outlined in ASTM B 193. The maximum resistance values shall conform to those
7、shown in Table 1. ENGINEERING MATERIAL SPECIFICATIONWSS-M1L120-A4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 3 3.4 INSULATION (SAE J1128) 3.4.1 The color of the insulation shall be specified on the engineering drawing of the component utilizing this mater
8、ial. Base and stripe color 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. There shall be two same color stripes. The stripes shall be on opposite sides of the cable. The stripe shall be
9、 of the same material as the insulation. The insulation and the color may show no evidence of peeling or cracking. 3.4.2 The insulating material shall be a polyvinyl chloride (PVC) material, homogeneous in character, and similar to SAE J1128 Type TWP. Insulation shall adhere closely to, but strip re
10、adily from the conductors, leaving them reasonably clean and in suitable condition for applying terminals. 3.4.3 Insulation thickness shall comply with the requirements of Table 2. Measure the minimum wall thickness as described in SAE J1128. 3.4.4 There shall be no separators permitted between the
11、core and the insulation. 3.5 CABLE QUALITY (TESTS) (SAE J1128) The finished cable shall meet all performance requirements of SAE J1128 (Revision date 2000-05) type TWP. These tests include strand coating, solderability, mechanical properties, dielectric, cold bend, flame resistance, fluid compatibil
12、ity, ozone resistance, pinch resistance, sandpaper abrasion resistance, hot water resistance and environmental cycling. Below are additional requirements and test modifications: 3.5.1 Original Tensile shall be a minimum of 2300 psi (15.9 MPa). 3.5.2 All cable shall be spark tested at 2000 Volts at t
13、he final cable handling process prior to being packaged for shipment. All spark failures must be removed. 3.5.3 Insulation shrinkage shall be tested by cutting in the middle of a cable section at least 1.0 m (3 ft) in length and immediately checking for exposed core. No core is allowed to extend pas
14、t the insulation. Care must be taken to assure the cable is not elongated prior to testing. ENGINEERING MATERIAL SPECIFICATIONWSS-M1L120-A4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 3 of 3 Table 1 SAE Wire Size Minimum number of Strands Conductor dia. Nom. Si
15、ze mm (in.) Reference onlyMinimum Conductor Area mm(cir. mil.) Minimum Strand Size mm (in.) Max. Resistance 20C (mohms/m) Reference only 22 7 0.73 (0.029) 0.325 (641) 0.243 (0.0096) 53.2 20 7 0.92 (0.036) 0.508 (1002) 0.304 (0.0120) 31.5 18 19 1.14 (0.045) 0.762 (1503) 0.226 (0.0089) 22.7 16 19 1.38
16、 (0.054) 1.128 (2226) 0.274 (0.0108) 15.7 14 19 1.77 (0.070) 1.859 (3668) 0.353 (0.0139) 9.29 12 19 2.23 (0.088) 2.928 (5777) 0.443 (0.0174) 5.90 10 19 2.81 (0.111) 4.663 (9200) 0.559 (0.0220) 3.72 Table 2 Finished Cable Diameter mm (in.) SAE Wire Size Minimum Insulation Thickness mm (in.) Nominal I
17、nsulation Thickness mm (in.) Maximum Minimum Nominal 22 0.28 (0.011) 0.4 (0.016) 1.63 (0.064) 1.47 (0.058) 1.55 (0.061) 20 0.28 (0.011) 0.4 (0.016) 1.80 (0.071) 1.64 (0.065) 1.72 (0.068) 18 0.28 (0.011) 0.4 (0.016) 2.02 (0.080) 1.86 (0.073) 1.94 (0.076) 16 0.28 (0.011) 0.4 (0.016) 2.25 (0.089) 2.09 (0.082) 2.17 (0.085) 14 0.28 (0.011) 0.4 (0.016) 2.66 (0.105) 2.50 (0.098) 2.58 (0.102) 12 0.32 (0.013) 0.44 (0.017) 3.20 (0.126) 3.04 (0.120) 3.12 (0.123) 10 0.35 (0.014) 0.50 (0.019) 3.88 (0.153) 3.72 (0.146) 3.80 (0.150)
