1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2006 09 29 Revised Para 3.4 and 3.4.1 M. Trapp 2003 08 12 Revised Para 3.0 inserted; Para 3.1, 3.2, 3.6, 4 deleted 1995 12 06 Activated M. Trapp Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 1 of 5 CABLE, P
2、RIMARY LOW TENSION, POLYETHYLENE WSS-M1L135-A1 INSULATED-THIN WALL 1. SCOPE The material defined by this specification is a low tension stranded cable insulated with cross-linked polyethylene. The cable is similar to SAE J1128, type TXL, but with a reduced insulation wall thickness. 2. APPLICATION T
3、his specification was released for automotive applications requiring the use of cross-linked insulation. Note: The assemblers of electrical wire harnesses shall use the bulk wire suppliers as shown in the Ford Motor Company Materials Approved Source List. 3. REQUIREMENTS 3.0 STANDARD REQUIREMENTS FO
4、R PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.3 CONDUCTOR (ASTM B 1/ASTM B 174) 3.3.1 The individual strands of the conductor shall be soft or annealed copper (hard copper wire may be used
5、for wire sizes smaller than SAE wire size 0.5 mm2(No. 20). Annealed copper strand elongation shall conform to ASTM B 174. Hard copper strand elongations shall conform to ASTM B 1. Strand dimensions shall be controlled to yield the cross-sectional area listed for the conductor of the finished cable p
6、er Table 1. Conductor area shall be determined by measuring individual strand diameters and calculating the sum of the individual strand areas. As an alternate method, conductor area may also be determined in accordance with ASTM B 263. 3.3.2 The strands shall be bunched per ASTM B 174. The maximum
7、lay length shall be as specified in ASTM B 174, Table 3, Column A. Conductor strand count shall comply with Table 1 of this specification. Missing strands are not allowed. 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
8、specimen is optional). Solder (optional) 25 mm along each end of the specimen. Condition the specimen for a minimum of 4 hours at 23 +/- 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
9、 C using the temperature correction method outlined in ASTM B 193. The maximum resistance values shall conform to those shown in Table 1. ENGINEERING MATERIAL SPECIFICATIONWSS-M1L135-A1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 2 of 5 3.4 INSULATION (SAE J112
10、8) 3.4.1 The color of the insulation shall be specified on the engineering drawing of the component utilizing this material. Base and stripe color codes shall correspond to SAE J1128. Where striping is specified, the stripe shall be a minimum of 0.3 mm. wide, but not more than 15% of the circumferen
11、ce of the wire. The stripe shall be of the same material as the insulation. If the insulation is dyed or painted, all the cable quality tests in section 3.4 and 3.5 must be performed on the finished product. The insulation and the color may show no evidence of peeling or cracking and must conform to
12、 the color tolerances specified. 3.4.2 The insulating material shall be flame retardant, homogeneous, cross-linked polyethylene, similar to SAE J1128, Type TXL. The material shall adhere closely to, but strip readily from the conductors, leaving them free of insulation and in suitable condition for
13、applying terminals. 3.4.3 Insulation thickness shall comply with the requirements of Table 2. Measure the minimum wall thickness of a 2000 mm specimen with an optical measurement device accurate to +/- 0.01 mm (other devices may be used but the referee method will be the optical device). Move the sa
14、mple approximately 400 mm and repeat the procedure for a total of five readings. The minimum insulation thickness shall comply with the values listed in Table 2. 3.5 CABLE QUALITY (TESTS) (SAE J1128) The Mechanical Properties, Dielectric, Flame, Crosslinking, and Cold Bend Tests shall all be conduct
15、ed in accordance with SAE J1128, Type TXL. Note: The following paragraphs shall be tested in accordance with SAE J1128, but with exceptions to the requirements as indicated. 3.5.1 Cable Diameter Measure the outside diameter of a 2000 mm specimen with an optical measurement device accurate to +/- 0.0
16、1 mm (other devices may be used but the referee method will be the optical device) by taking a minimum of 2 readings approximately 90 apart at each cross section. Move the sample approximately 400 mm and repeat the procedure for a total of five cross-sections. The mean of all the readings will deter
17、mine the outside diameter of the cable. The outside diameter will conform to the values listed in Table 2. 3.5.2 Pinch Test (SAE J1128) Values as specified in Table 3 of this document. 3.5.3 Heat Shrinkage (FLTM BB 101-15) Use a 200 mm sample for the test. The maximum insulation shrinkage shall not
18、exceed 4%. ENGINEERING MATERIAL SPECIFICATIONWSS-M1L135-A1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 3 of 5 3.5.4 Ozone Resistance (For Initial Qualification Only) (SAE J1128) There shall be no splits or cracks. See Table 4 for mandrel sizes and weights. 3.5.
19、5 Abrasion Resistance (Sandpaper Tape) (SAE J1128) Conduct the test using the bracket sizes and weights specified in Table 3 of this document. Abrasion resistance requirements are specified in Table 3. 3.5.6 Long Term Aging (For Initial Qualification Only) Strip 25mm of insulation from each end of a
20、 600 mm specimen. Condition the specimen for 3000 hours in a circulating air oven at a temperature of 125 +/- 2 C. Remove the specimen from the oven and allow it to remain at 23 +/- 5 C for a minimum of 4 hours. After this time perform one of the following tests: 1) Rotatable mandrel-fix one end of
21、the specimen to the mandrel and attach a weight to the free end of the specimen. Wind at least 1/2 turn, but no more than 3 turns, around the mandrel at a uniform rate of 1 turn in 10 seconds. See Table 4 for weights and mandrel sizes. 2) Stationary mandrel-wind at least 1/2 turn, but no more than 3
22、 turns, around the mandrel. Subject the specimen to the Dielectric test. There shall be no dielectric breakdown of the insulation. 3.5.7 Fluid Compatibility Remove 25 mm of insulation from each end of a 1000 mm specimen of cable and twist the two ends together. Measure the outside diameter as descri
23、bed in 3.4.1. Immerse one specimen in each of the fluids described in Table 5 for 20 hours. A maximum of 50 mm of each end of the specimen may protrude above the fluid. Withdraw the specimen and remove any excess fluid. Allow the specimen to remain at 23 +/- 5 C for approximately four hours. After t
24、he elapsed time, measure the outside diameter of the specimen and compute the percent diameter change. Perform one of the following tests on the specimen: 1) Rotatable mandrel-fix one end of the specimen to the mandrel and attach a weight to the free end of the specimen. Wind at least 1/2 turn, but
25、no more than 3 turns, around the mandrel at a uniform rate of 1 turn in 10 seconds. See Table 4 for weights and mandrel sizes. 2) Stationary mandrel-wind at least 1/2 turn, but no more than 3 turns, around the mandrel. Subject the specimen to the Dielectric test. There shall be no dielectric breakdo
26、wn of the insulation. ENGINEERING MATERIAL SPECIFICATIONWSS-M1L135-A1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 4 of 5 3.5.8 Insulation Fault Test of Complete Delivery (UL Test Method 1581, Section 900) Apply test voltage of 2 KV AC. All the wire must go thro
27、ugh spark tester during extrusion process, and all spark outs must be removed from complete delivery. Table 1 SAE Wire Size Minimum Number of Strands Conductor dia. Nom. Size mm Conductor Area mm2 Minimum Maximum Max Resistance 20 C (mohms/m) 22 7 0.76 0.34 0.36 54.4 20 7 0.97 0.54 0.58 37.1 18 19 1
28、.17 0.78 0.83 24.7 16 19 1.45 1.18 1.27 18.5 14 19 1.80 1.88 2.01 12.7 Note: Conductor areas are based on SAE J1128 minimums where applicable, with a 7% tolerance. Table 2 SAE Wire Size Minimum Insulation Thickness mm Nominal Insulation Thickness Mm Finished Cable Diameter mm maximum minimum nominal
29、 22 0.20 0.25 1.35 1.19 1.27 20 0.20 0.25 1.55 1.40 1.47 18 0.20 0.25 1.75 1.60 1.68 16 0.20 0.25 2.03 1.88 1.96 14 0.24 0.30 2.49 2.34 2.41 Table 3 SAE Wire Size No. Bracket Size Weight (with Bracket) Kg Min. Pinch Resistance Kg Minimum Abrasion Resistance mm 22 A 0.23 1.2 250 20 A 0.23 1.5 300 18
30、A 0.23 1.5 350 16 A 0.23 2.0 400 14 B 0.23 2.0 450 ENGINEERING MATERIAL SPECIFICATIONWSS-M1L135-A1 Printed copies are uncontrolled Copyright 2006, Ford Global Technologies, LLC Page 5 of 5 Table 4 Mandrel Diameter (mm) Weight SAE Wire Size A B Kg 22 25 6 0.68 20 25 6 0.68 18 25 13 0.68 16 25 13 0.68
31、 14 75 13 1.4 Legend: A = Physical properties, Long Term Aging, Cold Winding, and Fluid Compatibility. B = Resistance to ozone. Table 5 Test Fluid Test Maximum Outer Temperature Diameter Change Name Referee Fluid (C +/- 3 C) (%) Engine Oil ASTM D 471 IRM 902 50 15 Gasoline ASTM D 471 Ref, Fuel C 25
32、15 Methanol ASTM D 471 Ref, Fuel K 25 15 Power Steering ASTM D 471 IRM 903 50 30 Auto. Trans. Citgo #33-123 50 25 Engine Coolant ASTM D 471 Service Fluid 104 50 15 Battery Acid H2SO4, Specific Gravity = 1.260 +/- 0.005 25 5 Windshield Washer 40% Methanol + 59.5% Water Solution + 0.5% Surfactant and Blue Dye 25 15 Note: The fluid compatibility tests are designed to simulate normal automotive exposure. For severe exposure, other tests may be necessary.
