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1、SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefr
2、om, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. TO PLACE A DOCUMENT ORDER; (724) 776-4970 FAX: (724) 776-0790 SAE WEB ADDRESS http:/w
3、ww.sae.org Copyright 2000 Society of Automotive Engineers, Inc. All rights reserved.Printed in U.S.A. SURFACE VEHICLE 400 Commonwealth Drive, Warrendale, PA 15096-0001 STANDARD Submitted for recognition as an American National Standard J1127 REV. MAY2000 Issued1975-11 Revised2000-05 Superseding J112
4、7 JAN95 (R) Battery Cable TABLE OF CONTENTS 1.Scope . 1 2.References. 1 3.Definitions. 3 4.General. 4 5.General Specifications . 5 6.Tests. 8 7.Reference Information 16 8.Notes 17 Appendix A Recommended Colors 18 Appendix B Sources for SAE Reference Materials 19 1.ScopeThis SAE Standard covers low t
5、ension battery cable intended for use at a nominal system voltage of 60 V DC (25 V AC) or less in surface vehicle electrical systems. The tests are intended to qualify cables for normal applications with limited exposure to fluids and physical abuse. 2.References 2.1Applicable PublicationsThe follow
6、ing publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE EA-1128Wire Color Charts SAE J311Fluid for
7、Passenger Car Type Automatic Transmission Dictionary of Materials and Testing SAE J1127 Revised MAY2000 -2- 2.1.2ASTM PUBLICATIONSAvailable from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959. ASTM B 33Standard Specification for Tinned Soft or Annealed Copper Wire ASTM B 174Standard S
8、pecification for Bunch-Stranded Copper Conductors for Electrical Conductors ASTM B 263Method for Determination of Cross-Sectional Area of Standard Conductors ASTM B 298Standard Specification for Silver-Coated Soft or Annealed Copper Wire ASTM B 354Definitions of Terms Relating to Uninsulated Metalli
9、c Electrical Conductors ASTM B 355Standard Specification for Nickel-Coated Soft or Annealed Copper Wire ASTM D 412Standard Test Methods for Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic ElastomersTension ASTM D 471Standard Test Method for Rubber PropertyEffect of Liquids ASTM D 573St
10、andard Test Method for Rubber Deterioration in an Air Oven ASTM E 145Standard Specification for GravityConvection and Forced-Ventilation Ovens ASTM F 1251Standard Terminology Relating to Polymeric Biomaterials in Medical and Surgical Device 2.1.3IEC PUBLICATIONAvailable from ANSI, 11 West 42nd Stree
11、t, New York, NY 10036-8002. IECElectricity, Electronics and Telecommunications, Multilingual Dictionary 2.2Related PublicationsThe following publications are provided for information purposes only and are not a required part of this specification. 2.2.1SAE PUBLICATIONSAvailable from SAE, 400 Commonw
12、ealth Drive, Warrendale, PA 15096-0001. SAE J156Fusible Links SAE J1067Seven Conductor Jacketed Cable for Truck Trailer Connections SAE J1128Low Tension Primary Cable SAE J1292Automobile, Truck, Truck-Tractor, Trailer, And Motor Coach Wiring SAE J1654High Voltage Primary Cable SAE J1673High Voltage
13、Automotive Wiring SAE J1678Low Voltage, Ultra Thin Wall Primary Cable 2.2.2ASTM DOCUMENTSAvailable from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959. ASTM B 1Standard Specification for Hard-Drawn Copper Wire ASTM B 3Standard Specification for Soft or Annealed Copper Wire ASTM B 8Con
14、centric-Lay-Stranded Copper conductors, Hard, Medium-Hard, or Soft ASTM B 78719 Wire Combination Unilay-Stranded Copper Conductors for Subsequent Insulation 2.2.3IEC PUBLICATIONAvailable from ANSI, 11 West 42nd Street, New York, NY 10036-8002. IEC 811-2-1Common test methods for insulating and sheath
15、ing materials of electrical cablesPart 2: Methods specific to elastomeric compoundsSection 1: Ozone resistance testHot set testMineral oil immersion test. 2.2.4ISO DOCUMENTSAvailable from ANSI, 11 West 42nd Street, New York, NY 10036-8002. ISO 6722Road vehiclesUnscreened 60 V and 600 V single core c
16、ablesTest methods, dimensions and requirements ISO 14572Road vehiclesRound, unscreened, 60 V and 600 V multicore sheathed cablesBasic and high performance test methods and requirements SAE J1127 Revised MAY2000 -3- 3.Definitions 3.1Additional Mass (Reference “Sandpaper Abrasion Resistance” Test)The
17、mass which is applied to the additional mass support rod. The combination of the forces exerted by the additional mass and the 0.63 N exerted by the remaining apparatus (bracket, additional mass support rod, and pivoting arm) is applied to the cable. 3.2Coated WireWire comprised of a given metal cov
18、ered with a relatively thin application of a different metal. (ASTM B 354) 3.3CableSee primary cable. 3.4ConductorA wire or combination of wires not insulated from one another, suitable for carrying an electrical current. (ASTM B 354) 3.5CoreSee conductor. 3.6Fluid CompatibilityThe ability of a cabl
19、e to resist the effects of various fluids found in surface vehicles. 3.7Hot PlateAn electrically heated device used to test thermoset cables. 3.8Low VoltageUsually considered to be 60 V DC (25 V AC). 3.9Minimum Wall (Thickness)The lowest allowable insulation thickness at any point. 3.10 NominalA sui
20、table approximate value used to designate or identify a component. 3.11 Ozone ResistanceThe ability of a material to withstand the deteriorating effect of ozone (surface cracking). SAE, Dictionary of Materials and Testing. 3.12 PlasticAny of numerous polymeric materials that are usually thermoplasti
21、c or thermosetting, of high molecular weight and that can be molded, cast, extruded, drawn, laminated, or otherwise fabricated into objects, powders, beads, films, filaments, fibers, or other shapes. (ASTM F 1251) 3.13 Primary CableThe single or multi-stranded, single conductor, insulated cable used
22、 to carry electric current, by attachment to the low voltage side of an ignition coil in surface vehicles. 3.14 SAE Wire SizeA system that indicates the cross sectional area of the conductor. The Metric SAE Wire Size is the approximate area of the conductor. The English SAE Wire Size number indicate
23、s that the area of the conductor approximates the area of the American Wire Gauge for the equivalent size. 3.15 SeparatorA thin layer used as a barrier to prevent mutually detrimental effects between different components of a cable such as between the conductor and insulation or between the insulati
24、on and the sheath. (IEC, Electricity, Electronics, and Telecommunications, Multilingual Dictionary) 3.16 Strip ForceThe peak axial force required to overcome the adhesion between the conductor and the insulation. 3.17 StrandSee wire. 3.18 Temperature Class RatingA class designation based on the rete
25、ntion of “Mechanical Properties” (tensile and elongation) after 168 h of heat aging at 30 C above the temperature class rating. SAE J1127 Revised MAY2000 -4- 3.19 ThermoplasticA plastic capable of being softened by heating and hardened by cooling through a temperature range characteristic of the pla
26、stic and, in the softened state, capable of being repeatedly shaped by flow into articles by molding, extrusion, or forming. (IEC, Electricity, Electronics and Telecommunications, Multilingual Dictionary) 3.20 ThermosetA plastic which, when cured by heat or other means, changes into a substantially
27、infusible and insoluble product. NOTEThermosets are often called thermosetting before curing and thermoset after cure. (IEC, Electricity, Electronics and Telecommunications, Multilingual Dictionary 3.21 Wire (Strand)A rod or filament of drawn or rolled metal whose length is great in comparison with
28、the major axis of its cross section. (ASTM B 354) 3.22 Wire SizeSee SAE wire size. 4.General 4.1Cable TypesSee Figure 1. Type STTStarter or Ground, Thin wall, Thermoplastic Insulated Type SGTStarter or Ground, General Purpose, Thermoplastic Insulated Type STRStarter or Ground, Thin Wall, Thermoset E
29、lastomer (Synthetic Rubber) Insulated Type SGRStarter or Ground, General Purpose, Thermoset Elastomer (Synthetic Rubber) Insulated Type STXStarter or Ground, Thin Wall, Cross (X) Linked Polyolefin Insulated Type SGXStarter or Ground, General Purpose, Cross (X) Linked Polyolefin Insulated Type STESta
30、rter or Ground, Thin Wall, Thermoplastic Elastomer Insulated Type SGEStarter or Ground, General Purpose, Thermoplastic Elastomer Insulated FIGURE 1CABLE TYPES, REFERENCE SECTION 1 SAE J1127 Revised MAY2000 -5- 4.2General Test ConditionsTest samples shall be preconditioned for at least 16 h at a room
31、 temperature of 23 C 5 C. Unless otherwise specified, all tests shall be conducted at this same temperature. 4.3TolerancesUnless otherwise specified, all values are considered to be approximate. 5.General SpecificationsThe finished cable shall meet the requirements for all tests specified in Figure
32、2 for each cable type. FIGURE 2GENERAL SPECIFICATIONS, REFERENCE SECTION 5 SAE J1127 Revised MAY2000 -6- 5.1ConductorsThe finished, uninsulated conductor, shall meet the elongation requirements specified in ASTM B 174. When tin, silver, or nickel coated wires are used, they shall withstand the appli
33、cable “Strand Coating” test specified in 6.1 and Figure 2. The cross sectional area of stranded conductors shall not be less than the values specified in Figure 3. The cross sectional area may be verified by measuring actual strand sizes or by using the weight method in ASTM B 263 with a calculated
34、factor to account for the twist loss. FIGURE 3CONDUCTORS, REFERENCE 5.1 5.2InsulationThe insulation shall be homogeneous and shall be placed concentrically within commercial tolerances about the conductor. The insulation shall adhere closely to, but strip readily from, the conductors leaving them in
35、 suitable condition for terminating. A separator shall be used between uncoated conductors and insulations with a sulfur cure. Separators are optional for other constructions. 5.3Outside DiameterThe “Outside Diameter” shall be measured at five separate cross sections spaced 50 mm apart with an optic
36、al device accurate to at least 0.01 mm. Other devices may be used; however, in case of dispute, the referee shall be the optical device. A minimum of two readings shall be taken at each cross section. The sample should be rotated 90 degrees between readings. The mean of the diameter readings shall d
37、etermine the finished cable diameter and shall be in accordance with Figure 4 for the various cable types. 5.4Minimum Wall ThicknessThe “Minimum Wall Thickness” shall be measured at five separate cross sections spaced 400 mm apart using the equipment described in 5.3. All individual minimum wall mea
38、surements must be in accordance with Figure 4. SAE J1127 Revised MAY2000 -7- FIGURE 4OUTSIDE DIAMETER AND MINIMUM WALL THICKNESS, REFERENCE 5.3 AND 5.4 6.Tests 6.1Strand CoatingThe “Strand Coating” test shall be conducted on individual strands prior to stranding and shall be conducted per ASTM B 33,
39、 B 298, or B 355. This test is not required for uncoated strands. 6.2Solderability25 mm of insulation shall be removed from a 300 mm sample of finished cable. 12 mm of the stripped end shall be immersed into a component lead tinning flux such as Kester #2164, water soluble flux for 3 to 5 s. The str
40、ipped end shall then be immersed in solder 30 to 40% Sn, remainder Pb at 400 to 425 C for 3 to 5 s. Other fluxes, solders, and temperatures may be used; however, in case of a dispute, the referee shall be the Kester #2164 and the solder and temperature shown in this specification. A visual inspectio
41、n shall reveal no area in the immersed section which is not covered by solder. 6.3Mechanical PropertiesAn accelerated aging test shall be conducted in accordance with ASTM D 412, D 573, E 145 Type II except using specimens of insulation removed from finished cable. The sample shall be stretched at a
42、 rate of 50 mm/min. 500 mm/min may be used as the strain rate; however, in case of a dispute, the referee method will be a 50 mm/min strain rate. The original and conditioned samples must both be elongated at the same strain rate. The original properties shall conform to the values shown in Figure 5
43、. Samples of insulation shall be aged 168 h in a circulating air oven. The test temperature shall be as shown in Figure 5. After aging, the tensile strength shall not be less than 80% of the original test value and the elongation shall not be less than 50% of the original test value. STE or SGE samp
44、les may be conditioned at the test temperature for 24 h prior to taking the original measurements. The samples will then be conditioned for an additional 168 h (192 h total). The tensile strength after 192 h of conditioning shall not be less than 80% of the measured value after 24 h. The elongation
45、after 192 h of conditioning shall not be less than 50% of the measured value after 24 h. SAE J1127 Revised MAY2000 -8- FIGURE 5MECHANICAL PROPERTIES AND ENVIRONMENTAL CYCLING TEST CONDITIONS, REFERENCE 6.3 AND 6.12 6.4Dielectric25 mm of insulation shall be removed from each end of a 600 mm sample of
46、 finished cable and the two ends twisted together. The loop thus formed shall be immersed in water containing 5% salt by weight at room temperature so that not more than 150 mm of each end of the sample protrudes above the solution. After being immersed for 5 h and while still immersed, the sample s
47、hall withstand the application of 1000 V rms at (50 to 60) Hz between the conductor and the solution for 1 min without failure of the insulation. 6.5Cold Bend25 mm of insulation shall be removed from each end of a 1000 mm sample of finished cable. The sample shall be placed in a cold chamber at 40 C
48、 2 C for a period of 3 h. While the sample is still at this low temperature, it shall be wrapped around a mandrel for a minimum of 180 degrees at a uniform rate of one turn in 10 s. The mass and mandrel size shall be as specified in Figure 6. Either a revolving or stationary mandrel may be used. Whe
49、n a revolving mandrel is used, fasten one end of the sample to the mandrel and the specified mass to the other end. No mass is required when using a stationary mandrel. A visual inspection shall reveal no cracks or splits. The sample is to be returned to room temperature and then subjected to the dielectric test specified in 6.4. SAE J1127 Revised MAY2000 -9- FIGURE 6COLD BEND AND FLUID COMPATIBILITY TEST CONDITIONS, REFERENCE 6.5 AND 6.7 6.6Flame ResistanceA 600 mm sample of finished cabl