1、GeneralSpecificationElectric/Electronic GME14022Single Core CablesNote: This standard may be applied only for current projects incl. Global Epsilon (37#). It isSuperceded for all future projects and replaced by GMW15626.1 Introduction 21.1 Scope 21.2 Mission / Theme 21.3 Classification 21.3.1 Nomina
2、l System Voltage Classes 21.3.2 Insulation Wall Dimension Classes 21.3.3 Temperature Classes 22 References 22.1 External Standards/Specifications 22.2 GM Group Standards/Specifications 23 Test Preparation and Evaluation 23.1 Resources 23.1.1 Calibration 23.1.2 Alternatives 33.1.3 Facilities 33.1.4 E
3、quipment 33.2 Test Samples 33.3 Conditioning 33.4 Documentation 33.4.1 Test Results 33.4.2 Deviations from Test Procedure 34 Requirements and Procedure 44.1 Material 44.1.1 Conductor 44.1.2 Insulation 44.1.3 Identification 44.2 Marking 44.3 Colors 44.3.1 Dual-Color Cables 44.4 Dimensions 44.4.1 Cabl
4、e Outside Diameter 44.4.2 Insulation Thickness 54.4.3 Conductor Diameter 74.4.4 Strand Diameter 74.5 Electrical Characteristics 74.5.1 Conductor Resistance 74.5.2 Withstand Voltage 84.5.3 Insulation Faults 94.5.4 Insulation Volume Resistivity 94.6 Mechanical Characteristics 94.6.1 Pressure Test at H
5、igh Temperature 94.6.2 Abrasion Resistance 104.6.3 Strip Force 124.6.4 Tensile Strength 124.7 Low Temperature Characteristics 124.7.1 Winding 124.7.2 Impact 144.8 Heat Aging Characteristics 154.8.1 Short Term Ageing 154.8.2 Long Term Ageing 154.8.3 Shrinkage by Heat 164.8.4 Thermal Overload 164.8.5
6、Thermal Stability in Wound State 164.9 Chemical Characteristics 174.9.1 Fluid Compatibility 174.9.2 Resistance to Ozone 184.9.3 Resistance to Hot Water 194.9.4 Environmental Cycling 194.10 Additional Characteristics 214.10.1 Density 214.10.2 Mycological Test 214.10.3 Flammability 215 Additional Requ
7、irements 215.1 Restircted Substances 215.2 Compatibility 216 Notes 216.1 Glossary 216.2 Acronyms, Abbreviations and Symbols 217 Additional Paragraphs 227.2 Evaluation Plan 228 Coding System 229 Release and Revisions 22 Copyright 2008 General Motors Corporation All Rights ReservedPublication Departme
8、nt: GME Specification CenterApril 2008 - Issue No. 2 Page 1 of 25PRD045 - VPRE ST 1 10/03 GME14022 GM EUROPE ENGINEERING STANDARDS9.1 Release 229.2 Revisions 22Appendix A 23Appendix B 251 Introduction1.1 Scope. This standard is based on ISO 6722, towhich additions have been made in several sections.
9、1.2 Mission / Theme. This standard specifiesdimensions, test methods and requirements forsingle-core cables. The purpose of the cables is tosupply current to power consuming components.1.3 Classification. Single-core cables are classifiedbythenominalvoltageofthesystemwherethecablesare used, by thewa
10、lldimensionof thecableinsulationand by the operating temperature.1.3.1 Nominal System Voltage Classes.60 V cables intended for use in road vehicleapplications where the nominal system voltage is 60VDC600 V cables intended for use inroad vehicle appli-cations where the nominal system voltage is in th
11、erange of (60.600) VDC inclusive.Note: For applications, where the nominal systemvoltage is 60 V the usage of thick wall cables isrequired.1.3.2 Insulation Wall Dimension Classes.R thin wallS thick wallU ultra thin wall1.3.3 Temperature Classes. Eight cable classeshave been defined in Table 1 to res
12、pond to thevarious temperatures encountered on vehicles.Note: Nothinginthisstandardsupersedesapplicablelaws and regulations.Note: In the event of a conflict between the Eng-lish and the domestic language, the English languageshall take precedence.2 ReferencesNote: Only the latest approved standards
13、are appli-cable unless otherwise specified.2.1 External Standards/Specifications.EN 590 EN 13602FMVSS 302 IEC 60068-2-10IEC 60811-1-1 IEC 60811-2-1ISO 1817 ISO 1183-3ISO 6722 ISO 84582.2 GM Group Standards/Specifications.B 040 1065 B 040 1073L 000 0102 GME8740GME L0003 GMW3059ON 1397 ON 2023 Test Pr
14、eparation and Evaluation3.1 Resources.3.1.1 Calibration. The test facilities and equipmentshall be in good working order and shall have a validcalibration label. Copyright 2008 General Motors Corporation All Rights ReservedPage 2 of 25 Issue No. 2 - April 2008PRD045 - VPRE ST G 10/03 GM EUROPE ENGIN
15、EERING STANDARDS GME14022Table 1: Temperature ClassesClass OperatingTemperatureLong-term AgeingTemperature 3000 hShort-term AgeingTemperature 240 hThermal OverloadTemperature 6 hC C C CA -40.+85 +852 +110 2 +135 2B -40.+100 +1002 +125 3 +150 2B+5 -40.+105 +1052 +130 3 +155 3C -40.+125 +1253 +150 3 +
16、175 3D -40.+150 +1503 +175 3 +200 3E -40.+175 +1753 +200 3 +225 4F -40.+200 +2003 +225 4 +250 4G -40.+225 +2254 +250 4 +275 4H -40.+250 +2504 +275 4 +300 43.1.2 Alternatives. Alternative test facilities andequipment may also be used. However, all mea-suring variables as specified in this standard sh
17、allbe determined correctly with respect to its physicaldefinition.3.1.3 Facilities.3.1.3.1 Ovens. When an oven is required, a naturalventilated oven shall be used.3.1.4 Equipment. As specified in the single tests.3.2 Test Samples. Number of test samples as spec-ified in each section.For cables of id
18、entical compound: Unless otherwisespecified, 0.35 mm2, 0.75 mm2,2.5mm2 and 16 mm2cable sizes shall be tested.The cables to be tested shall be manufactured underfull production conditions.No parts out of prototype tools shall be used.3.3 Conditioning. Test samples for all tests shallbe preconditioned
19、 for 16 h at a temperature of(+23 5) C (room temperature) and a relativehumidity of (50 6) %. Unless otherwise specified,all tests other than “in process” tests shall be con-ducted at this temperature.3.4 Documentation. Samples of components ormaterial released to this standard shall be tested forco
20、nformity with the requirements of this standard andapproved by the responsible GM Department prior tothe start of delivery of production level componentsor materials.Any change to the component or materiale.g. design,function, properties, manufacturing process and/orlocation of manufacture requires
21、a new releaseof the product. It is the sole responsibility of thesupplier to provide the customer, unsolicited, withdocumentation of any change or modification to theproduct/process, and to apply for a new release.Note: The two major substances of the total com-pound shall be declared in percentage
22、by mass andpercentage by volume.If not otherwise agreed to the entire verification testshall be repeated and documented by the supplierprior to start of delivery of the modified or changedproduct. In some cases a shorter test can be agreedto between the responsible GM Department and thesupplier.3.4.
23、1 Test Results. Test results shall be reported ina test report (see example in Appendix B). The testreport shall included as minimum:Name of the supplierDateDesignation of the productIMDS-ID and information, if the IMDS datasheethas been approved by the customerReference to the used test methodTest
24、result and interpretation of test result3.4.2 Deviations from Test Procedure. Deviationsfrom the requirements of the test procedures shallhave been agreed upon. Such requirements shall Copyright 2008 General Motors Corporation All Rights ReservedApril 2008 - Issue No. 2 Page 3 of 25PRD045 - VPRE ST
25、U 10/03 GME14022 GM EUROPE ENGINEERING STANDARDSbe specifiedon componentdrawings, test certificates,reports etc.4 Requirements and ProcedureNote: Where no tolerance is specified, all values areto be considered to be approximate.4.1 Material.4.1.1 Conductor. Conductorsshallconsistofcopperwire to EN 1
26、3602. The material of the conductor shallbe documented according to EN 13602. The conduc-tor surface shall be copper, tin- or silver-plated.4.1.2 Insulation. Conductors shall be insulated withmaterial complying with the requirements in this stan-dard. Insulationshallbe smoothandfree from cracks,pitt
27、ing and other defects visible to the naked eye. Theinsulationmaterialshallensure adequateinsulation ofelectric cables at temperatures as per Table 1.Table 2 defines the material codes for insulationmaterial. If the code 6 is used, the material and thetemperature class shall be explicitely expressed
28、onthe test reports and test certificates.Table 2: Insulation Material CodeCode InsulationMaterialTemperatureClasssee Table 11 PVC B2 XLPE C3 XLPE D4 ETFE E5 SIR F6 FEP F7 Other materials Select classaccording toTable 14.1.3 Identification. As part of the work of typetesting, material identification
29、shall be carried outby means of determination of various chemicaland physical properties and characteristics in orderto determine the properties and characteristics oftype-tested electrical conductors.This is done in order to obtain reference values thatwould be needed in the event of any claims. De
30、par-tures from these reference values exceeding normaltolerances shall initiate more extensive inspection inaccordance with this Standard.4.1.3.1 IR-Spectrum. This method is used for identi-fication of organic compounds and takes place on thebasis of the position and intensity through molecularmovem
31、ent provoked absorption.The analysis of the insulation shall be performed indelivery conditionandafter short-termageing(240 h).Note: Depending on the color batch, small changesand/or deviations are permitted.4.2 Marking. The usage of the marking is to beestablished by agreement between customer ands
32、upplier.Color- and laser marking are permitted. When mark-ing stamped into the insulating material, the raisedstampingshallbelessthan0.020mmand theembed-ded stamping less than 0.010 mm.Finalinspectionandapprovalaregivenbytherespon-sible GM Department, concerning readability, durabil-ity and sealing
33、effect to single-wire sealings.Ifnototherwisespecified,cablesshallbepermanentlymarked according to ON 1397. In addition the sup-pliers type designation shall be added. This markingshall be repeated at intervals not exceeding 200 mmalong the conductor.4.3 Colors. Colors of insulation shall agree reas
34、on-ably closely with the specified colors as shown inGME8740.4.3.1 Dual-ColorCables. Permitted combinations ofcolors can be found in GME8740.Color coding of conductors (painting of neutral con-ductors in different colors) shall not be employed.4.4 Dimensions. The cables of type R shall fulfill thedi
35、mension requirements according to Table 3. Thecables of type S shall fulfill the dimension require-ments according to Table 4. The cables of type Ushall fulfill the dimension requirements according toTable 5.4.4.1 Cable Outside Diameter.Test SamplesPrepareatestsampleof3m.ApparatusUse a measuring dev
36、ice that does not cause defor-mation.ProcedureCable external diameter shall be measured at threepoints along the length of the cable, separated by adistance of not less than 1 m. Copyright 2008 General Motors Corporation All Rights ReservedPage 4 of 25 Issue No. 2 - April 2008PRD045 - VPRE ST G 10/0
37、3 GM EUROPE ENGINEERING STANDARDS GME14022The diameter shall be taken to be the mean value ofthree measurements at each point. The measure-ments shall be made peripherally with a mutual dis-placement of 10 xValues of number of strands and strand diameter aregiven for alternative design. It is the ma
38、ximum con-ductor resistance that is decisive for these measure-ments.MeasurementThe shape of the strand may not be altered by themeasurement process.Measurement accuracy: 0.01 mm.Interpretation of Test ResultsThe strand diameter shall be in accordance with therequired strand diameter (see Table 3, T
39、able 4 andTable 5).4.5 Electrical Characteristics.Name Requirement TestConductor Resistance Table6 4.5.1Withstand Voltage no breakdownduring test4.5.2Insulation Faults no breakdownduring test4.5.3Insulation VolumeResistivity 109 mm 4.5.44.5.1 Conductor Resistance.Test SamplesPrepare a test sample of
40、 1 m length plus the lengthnecessary for connections. Other lengths may beused providing that the resistance reading is correctlyadjusted. The ends of the test sample may be sol-dered.ApparatusUse a resistance-measuring device with accuracy towithin 0.5 % of the measured value and a ther-mometer wit
41、h an accuracy of 0.5 %.ProcedureMeasure the temperature of the test sample and theunsoldered length. Take care to ensure that connec-tions are secure. Measure the resistance of the testsample. Correct the measured value using the follow-ing equation:t is the conductor temperature at the time of mea-
42、suring, expressed in C.R20 isthecorrectedconductorresistance attheref-erence temperature of 20 C, expressed in m /m. Copyright 2008 General Motors Corporation All Rights ReservedApril 2008 - Issue No. 2 Page 7 of 25PRD045 - VPRE ST U 10/03 GME14022 GM EUROPE ENGINEERING STANDARDSRt is the conductor
43、resistance measured at theconductor temperature in m .L is the unsoldered conductor length, expressed inm.Thevalueof0.00393isthetemperature coefficientforcopper with 100 % conductivity at temperatures near20 C.Interpretation of Test ResultsThe conductor resistance shall comply with therequired condu
44、ctor resitance value (see Table 6).Table 6: Conductor Resistance RequirementConductor Resistance perLength at 20 CCross SectionPlain Copper Sn-platedCopperMax Maxmm2 m /m m /m0.35 54.4 55.50.5 37.1 38.20.75 24.7 25.41.0 18.5 19.11.5 12.7 13.02.5 7.60 7.824 4.71 4.856 3.14 3.2310 1.82 1.8516 1.16 1.1
45、825 0.743 0.75735 0.527 0.53850 0.368 0.37570 0.259 0.26495 0.196 0.200120 0.153 0.1564.5.2 Withstand Voltage.Test SamplePrepare a test sample of a minimum length of350 mm, strip 25 mm of insulation from each end andtwist the conductor ends together to form a loop.ApparatusPartially fill a non-condu
46、ctive vessel with saltwater(3 % by weight of NaCl in water) with the ends of thetestsampleemergingabovethe bathas shown inFig-ure 1. Use a voltage source of a frequency of 50 Hzor 60 Hz.Procedure60 V CableImmerse the test sample in the bath as shownin Figure 1 for 4 h and apply a test voltage of1 kV
47、 (rms) for 30 min between conductor and thebath. Thenincrease the voltageatarate of500 V/suntil the following value is reached:3 kV (rms) for cables 2.5 mm2.Interpretation of Test ResultsAny combustion flame of insulating material shallextinguish within 30 s, and a minimum of 50 mm ofinsulation at t
48、he top of the test sample shall remainunburned.Figure 9: Apparatus forresistancetoflameprop-agation test(All dimensions in mm.)1 Test sample2 Bunsen burner5 Additional Requirements5.1 Restircted Substances. All materials suppliedto this standard must comply with the requirements ofGMW3059, RestrictedandReportableSubstancesfor Parts.5.2 Compatibility. Compatibility with other materials(i.e. tabes, convoluted conduits etc.) and/or comp
