1、GM DAEWOO Auto & Technology EDS Engineering, GM DAEWOO Auto & Technology Standards METHOD OF TEST FOR INSULATION CABLE Do Not Use on New Programs. Being Replaced by GMW3172 EDS-T-5702 ISSUED DATE: 1991. 08. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 (Superceded) EDS-T-5702METHOD OF TEST FOR INSULATION
2、 CABLE PAGE: 1/7 ISSUED DATE: 1991. 08. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Note: This standard may be applied only for current project (incl. T255 Program). It is Superceded for all future projects and replaced by GMW3172. 1. PURPOSE The standard aims at performing
3、an accurate test by specifying the test method, condition and standard for insulated wire used for automobile. 2. SCOPE This standard specifies all the unit insulated cable used by GMDAT excluding the high frequency and high tension wire. (However, when there are separate standards or drawings of a
4、higher order, they shall prevail.) 3. DEFINITION 3.1. Insulated wire: The insulated wire refers to a connector to connect circuits or devices to each other electrically. 3.2. Native copper: Native copper refers to pure copper. 3.3. Bronze: Bronze refers to the alloy of tin and copper. 4. PREPARATION
5、 4.1. Unless otherwise specified in the drawing, prepare an insulated cable less than 2M in length. 4.2. Unless otherwise specified in the test procedure, perform the test at (+235). 4.3. Prepare the measuring instruments and equipment for dimension measurement (Refer to the standard). 5. REGULATION
6、 AND STANDARD FOR UNIT INSULATED WIRE Conform to Table 1. However, when it is specified in the drawing specially, the drawing specification prevails. Table 1 Resistance value of conductor Conductor cross-section Number of wires Wire dia. X Conductor dia. X Native copper m /M Bronze m /M Thickness of
7、 cover X Whole dia. of insulated cable X 0.05 7 0.11 0.4 349 356 0.3 1.0 0.22 7 0.21 0.7 84.8 86.5 0.3 1.3 0.38 12 0.21 0.9 54.4 55.5 0.3 1.5 0.5 16 0.21 1.1 37.1 38.2 0.6 2.3 0.75 24 0.21 1.3 24.7 25.4 0.6 2.5 1.0 32 0.21 1.5 18.5 19.1 0.6 2.7 1.5 30 0.26 1.8 12.7 13.0 0.6 3.0 2.5 50 0.26 2.2 7.60
8、7.82 0.7 3.6 4.0 56 0.31 2.8 4.71 4.85 0.8 4.4 EDS-T-5702METHOD OF TEST FOR INSULATION CABLE PAGE: 2/7 ISSUED DATE: 1991. 08. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Continued Resistance value of conductor Conductor cross-section Number of wires Wire dia. X Conductor dia
9、. X Native copper m /M Bronze m /M Thickness of cover X Whole dia. of insulated cable X 6.0 84 0.31 3.4 3.14 3.23 0.8 5.0 10.0 80 0.41 4.5 1.82 1.85 1.0 6.5 16.0 126 0.41 6.3 1.16 1.18 1.0 8.3 6. TEST CONDITION AND SPECIFIED VALUE Conform to Table 2. However, when it is specified in the drawing spec
10、ially, the drawing specification prevails. Table 2 Test item Grade Classification A B C 0.5 max. 3 q (Effective value) 3 q (Effective value) 3 q (Effective value) Insulation test 0.5 min. 5 q (Effective value) 5 q (Effective value) 5 q (Effective value) Test voltage 1 q (Effective value) 1 q (Effect
11、ive value) 1 q (Effective value) 0.5 max. Breakdown voltage 3 q (Effective value) 3 q (Effective value) 3 q (Effective value) Test voltage 1 q (Effective value) 1 q (Effective value) 1 q (Effective value) Breakdown voltage when applying voltage for 30 min. 0.5 min. Breakdown voltage 5 q (Effective v
12、alue) 5 q (Effective value) 5 q (Effective value) Test temperature (70 2) (70 2) (70 2) Insulation resistance Resistance capacity 103X min. 103X min. 103X min. High temperature/ High tension test Test temperature (70 2) (105 2) (120 2) High temperature exposure test Test temperature (105 2) (120 2)
13、(155 2) Test temperature (150 2) (150 2) - Thermal deformation test Change rate Within 4% Within 4% Flame trans. time 30 seconds 30 seconds 15 seconds Flame transmission resistance test Extinguishing time 30 seconds 30 seconds 70 seconds Low temperature exposure test Test temperature in winding test
14、 (-25 3) (-25 3) (-25 3) 0.5 to 1.0 0.5 b 0.5 b 0.5 b Wire holding strength test 1.0 to 2.5 1.25 b 1.25 b 1.25 b Test temperature (90 2) (90 2) (90 2) Oil resistance test Change rate 4% 4% Within 20% Fuel resistance test Change rate 6% 6% Within 30% EDS-T-5702METHOD OF TEST FOR INSULATION CABLE PAGE
15、: 3/7 ISSUED DATE: 1991. 08. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology 7. TEST METHOD 7.1. Insulation test 7.1.1. The cable shall not exhibit insulation breakdown when applying a specified AC voltage. 7.1.2. The frequency of the AC voltage shall be 50 Hz or 60 Hz. 7.1.3. A
16、pplying time of the AC voltage shall be one sec. 7.2. Breakdown voltage when applying the voltage for 30 min 7.2.1. Prepare a test sample of 1200mm. 7.2.2. When applying the specified voltage for 30 minutes as specified in Fig. 1 after leaving the test sample in 3% salt solution at room temperature
17、(235) for 4 hours, the test sample shall not exhibit insulation breakdown. 7.2.3. When raising the voltage to the specified voltage of 500V/sec after applying the voltage for 30 minutes, the test sample shall not exhibit insulation breakdown. 7.3. Insulation resistance 7.3.1. Prepare the a sample of
18、 5000mm. 7.3.2. Leave it in running water of the specified temperature for 2 hours. 7.3.3. Apply a DC voltage of 500V between the conductor and water for 1 minute to measure the insulation resistance. 7.3.4. Calculate by the following formula. dDRIlog572,2= Where) : Resistance-capacity(X ) L : Lengt
19、h of test sample submerged in the water(X ) R : Insulation resistance( ) D : Outside diameter of insulated cable(X ) d : Diameter of conductor(X ) 7.4. High temperature/high pressure test 7.4.1. Prepare a test sample of 100mm. 7.4.2. Expose the test sample at the specified temperature in well-ventil
20、ated place for 4 hours under a specified pressure. Note) 2208.0 iDiG = Where) G : Specified pressure(b ) D : Outside diameter of test sample(X ) i : Thickness of insulation(X ) EDS-T-5702METHOD OF TEST FOR INSULATION CABLE PAGE: 4/7 ISSUED DATE: 1991. 08. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM
21、DAEWOO Auto & Technology 7.4.3. Take out the test sample and submerge it in cold water for 10 seconds for cooling. 7.4.4. Evaluate cross-section width and depth using a microscope. 7.4.5. When dividing the dented portion into 6 equal parts, the depth of dent shall not deviate from mean thickness by
22、more than 50%. 7.5. High temperature exposure test 7.5.1. Prepare a test sample of 500mm. 7.5.2. Expose the test sample at the specified temperature vertically in well-ventilated place for 48 hours. 7.5.3. Cool the test sample at room temperature of (235). 7.5.4. Wind the test sample around a round
23、metal bar clockwise, and then counter-clockwise closely 4 times or more. 7.5.5. The diameter of the round metal bar, winding speed and winding weight shall conform to Table 1. 7.6. Thermal deformation test 7.6.1. Prepare a test sample of 200mm. 7.6.2. Expose the test sample horizontally at the speci
24、fied temperature in well-ventilated place for 15 minutes. 7.6.3. Cool the test sample at room temperature of (235). 7.6.4. The insulator shall be free from wrinkle or crack, and the deformation of length shall be within the specified percent. 7.7. Spark transmission resistance test 7.7.1. Prepare a
25、test sample of 500mm. 7.7.2. Adjust the inside diameter of the Bunsen burner to 9mm, flame height to 100mm and size of blue conical flame to 50mm. Note : It shall be capable of melting copper wires of (0.70.03)mm in diameter within 4 to 6 seconds. 7.7.3. Test apparatus shall conform to Fig. 2. 7.7.4
26、. When extinguishing the gas flame after applying it for a specified time, it shall be extinguished within the specified time. 7.8. Low temperature exposure test 7.8.1. Prepare a test sample of 400mm. 7.8.2. Expose the test sample at the specified temperature vertically in well-ventilated place for
27、4 hours. 7.8.3. When winding 3 times in a thermostatic container, the conditions shall conform to Appendix Table 1 and EDS-T-5702METHOD OF TEST FOR INSULATION CABLE PAGE: 5/7 ISSUED DATE: 1991. 08. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology there shall be no breaks and crac
28、ks. 7.9. Wire holding strength test 7.9.1. Prepare a test sample of 150mm. 7.9.2. Peel the insulator by more than 100mm. 7.9.3. When applying a specified load to the exposed conductor that faces downward with a steel plate that has similar holes mounted on it horizontally, there shall be no abnormal
29、ity in wires and conductor. 7.10. Oil resistance test 7.10.1. Prepare a test sample of 500mm. 7.10.2. Expose the test sample to No. 1 oil according to ISO 1817 at a specified temperature for 48 hours. 7.10.3. When it is exposed, let it project above the oil surface by about 50mm. 7.10.4. Cool the te
30、st piece at a room temperature of (235). 7.10.5. Wind the test sample around a round metal bar clockwise, and then counter-clockwise closely for 4 times or more. 7.10.6. The diameter of the round metal bar, winding speed and winding weight shall conform to Table 1. 7.11. Fuel resistance test 7.11.1.
31、 Prepare a test sample of 500mm. 7.11.2. Expose it to fuel C according to ISO 1817 at a room temperature of (235) for 30 minutes. 7.11.3. When it is exposed, let it project above the fuel surface by about 100mm. 7.11.4. Dry the test piece at room temperature of (235). 7.11.5. Wind the test sample on
32、 a round metal bar clockwise, and then counter-clockwise closely for 4 times or more. 7.11.6. The diameter of the round metal bar, winding speed and winding weight shall conform to Table 1. EDS-T-5702METHOD OF TEST FOR INSULATION CABLE PAGE: 6/7 ISSUED DATE: 1991. 08. 20 REVISED DATE: 2008. 10. 21 V
33、ERSION: 3 GM DAEWOO Auto & Technology Appendix Table 1. Winding Speed, Diameter of Round Bar and Winding Weight Diameter of electrical wire(mm) Dia. of round bar (X 1) Dia. of round bar(X 2) Winding weight (b ) Winding speed(1 cycle/sec2) 2.5 max. 2 6 0.5 1.0 Over 2.5 to 3.0 3 10 2.5 1.0 Over 3.0 to
34、 4.0 4 15 5.0 1.0 Over 4.0 to 5.0 5 20 5.0 1.0 Over 5.0 to 6.0 6 30 10.0 0.5 Over 6.0 to 7.0 8 40 10.0 0.5 Over 7.0 to 8.2 10 50 15.0 0.5 Over 8.2 to 9.5 12 - 15.0 0.5 Over 9.5 to 11.0 15 - 20.0 0.5 Over 11.0 to 12.5 20 - 20.0 0.2 Over 12.5 to 15.0 30 - 30.0 0.2 Over 15.0 to 17.0 50 - 30.0 0.2 Over
35、17.0 to 20.0 75 - 30.0 0.2 Note 1) It shall be applied to high temperature exposure test, oil resistance test and fuel resistance test applied to low temperature exposure test. Note 2) It shall be applied to low temperature exposure test. Figure 1. Device for breakdown voltage test EDS-T-5702METHOD OF TEST FOR INSULATION CABLE PAGE: 7/7 ISSUED DATE: 1991. 08. 20 REVISED DATE: 2008. 10. 21 VERSION: 3 GM DAEWOO Auto & Technology Figure 2. Device for flame transmission resistance test
