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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. QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8512 FAX: (724) 776-0243 TO PLACE A DOCU
3、MENT ORDER; (724) 776-4970 FAX: (724) 776-0790 SAE WEB ADDRESS http:/www.sae.org Copyright 1998 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 Sta
4、ndard J1614 ISSUED MAR1998 Issued1998-03 Wiring Distribution Systems for Construction, Agricultural, and Off-Road Work Machines 1.ScopeThis SAE Standard specifies requirements and design guidelines for electrical wiring systems of less than 50 V and cable diameters from 0.8 to 19 mm2 used on constru
5、ction, agricultural, and general purpose industrial categories of off-road self-propelled work machines as defined in SAE J1116. 2.References 2.1Applicable PublicationsThe following publications form a part of the specification to the extent specified herein. Unless otherwise indicated, the latest r
6、evision of SAE publications shall apply. 2.1.1SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE J163Low Tension Wiring and Cable Terminals and Splice Clip SAE J378Marine Wiring SAE J1116Categories of Off-Road Self-Propelled Work Machines SAE J1127Battery Cabl
7、e SAE J1128Low Tension Primary Cable SAE J1493Shielding of Starter System Energization SAE J1908Electrical Grounding Practice 2.1.2IEC PUBLICATIONAvailable from International Electrotechnical Commission, 3, rue de Verambe, P.O. Box 131, 1211 Geneva 20, Switzerland. IEC 617Graphical Symbols for Diagr
8、ams 2.2Related PublicationsThe following publications are provided for information purposes only and are not a required part of this document. SAE J562Loom, Asphalt Impregnated SAE J821Electrical Systems for Construction and Industrial Machines SAE J1614 Issued MAR1998 -2- 3.Definitions 3.1Electrica
9、l CircuitsAn electrical circuit includes all the components and connecting cables, starting from the electrical energy source, going to the functional component(s) and the return route to the energy source. 3.2Electrical ComponentAn electrical component is normally a combination of parts, sub-assemb
10、lies, or assemblies and is a self-contained element intended to store, generate, distribute, alter, or consume electrical energy. 3.3Conductor(s)The current carrying element(s) in a cable. 3.4Electrical CableInsulated stranded electrical conductor used to establish a single current path. 3.5HarnessA
11、 group of two or more cables bundled together. 3.6TerminalAn electrically conductive device attached to a cable to facilitate connection to an electrical component, cable, or termination. 3.7ConnectorA coupling device which provides an electrical and/or mechanical junction between two cables or betw
12、een a cable(s) and an electrical component. 3.8WiringCollectively, the cables, harnesses, connectors, terminations, and supporting components used in the electrical wiring distribution system. 4.Wiring Design 4.1Cable SelectionThe preferred cable shall meet the requirements of SAE J1127 and SAE J112
13、8 type SXL. Other cable types may be required for specific applications. 4.2Cable Size DeterminationCable size is determined by consideration of the following factors: a.Cable mechanical strength b.Maximum temperature rise c.System voltage drops d.Selected connectors 4.2.1Apply the procedure in Figu
14、re 1, Cable Sizing Flowchart, for determining cable sizes. These factors vary in importance depending upon the application. Details specific to each are found in the following paragraphs. 4.2.1.1Configure the electrical circuit including grounds and connectors. 4.2.1.2Determine current requirements
15、and cable lengths. 4.2.1.3Determine fuse, circuit breaker, or other requirements applying appropriate de-rating factors. 4.2.1.4A minimum size cable, or larger, shall be selected which meets all the previous requirements. 4.2.2For mechanical strength, the minimum cable size recommended shall be 0.8
16、mm2 in harnesses and/or protected areas. A cable size of 1 mm2 shall be the minimum cable size in areas susceptible to physical damage, or where one or two cables are extended from the harness. SAE J1614 Issued MAR1998 -3- FIGURE 1CABLE SIZING FLOWCHART 4.2.3The maximum temperature of the cable with
17、 steady-state currents shall not exceed the continuous duty temperature rating of the cable insulation, connector molding material, or other materials which the cable may come in contact with. 4.2.4FAULT CONDITION MAXIMUM TEMPERATURE RISE 4.2.4.1To control maximum temperature rise in a fault conditi
18、on the cable must be sized for the circuit protection installed in the circuit. When a circuit breaker is used, it is important that the cable and the breaker be sized in such a way that the thermal circuit breaker “heats“ at a rate higher than the cable to protect the cable from damage. Table 1 lis
19、ts the minimum cable sized for given thermal circuit breakers. In ambient temperatures up to 65 C, the circuit breaker must be de-rated typically to 70% of its rating to prevent possible opening under steady-state conditions. In a fault condition, it is typical for the temperature of the cable to be
20、 raised by the fault current in the cable. TABLE 1CABLE SIZED FOR THERMAL CIRCUIT BREAKERS 70% Load Operating Current (A) Circuit Breaker Rating (Thermal type) (A) Smallest Cable Size Acceptable (mm2) Calculations for this column are found in Appendix A. 5.27.50.8 7.0101 10.5152 14203 21305 28408 42
21、6013 568019 SAE J1614 Issued MAR1998 -4- 4.2.5For Steady-State Thermal Capacity, the selected cable size should be verified by load testing. Table 2 gives the values of currents permissible based on the assumptions of 30 C rise for cables bundled in a harness and 10 C rise of a single cable in free
22、air due to steady-state current heating. Circuit protection should be sized for the smaller size wire within the circuit. 4.2.6INTERMITTENT LOAD CYCLESFor circuits where the electrical load is of a short duration, a 90-s rating can be used. As an example, a cable which is at a 40 C ambient and is al
23、lowed to thermally rise to 150 C. A short-term rating can be calculated based on its thermal mass. Based on the formula , the following ratings and sizings would be established. Please see Appendix A for the derivation of the constant. 8 mm2 is rated 90 A 13 mm2 is rated160 A 19 mm2 is rated250 A 4.
24、2.7The procedure used to determine voltage drop with respect to cable size begins with establishing maximum allowable voltage drop VD (volts), length of cable l (mm), and maximum operating current in circuit i (A). 4.2.7.1Calculate cable resistance in micro-ohms/mm (r) as shown in Equation 1: (Eq. 1
25、) 4.2.7.2After finding the calculated resistance, select the cable size from Table 3. TABLE 2STEADY-STATE THERMAL CAPACITY(1) 1.Dimensions used in calculating this table are typical industry values. Values found in this table are based on the calculations found in Appendix A. Cable Size (mm2) Rating
26、s (A) 0.87.5 110 214 320 529 841 1360 1982 TABLE 3VOLTAGE DROP RESISTANCE Cable Size (mm2) Resistance ( ) 190.814 131.388 82.254 53.576 35.676 29.088 114.370 0.821.496 Current Area -13.82= r VD li -106= SAE J1614 Issued MAR1998 -5- 4.2.7.3Examples of typically acceptable run lengths with a 1 V drop
27、in a 12 V system are given on Table 4. Please note certain systems require voltage drops as small as 0.1 V. Calculation of the full system voltage drop is always recommended. Maximum voltage drop shall be established to provide optimum performance and reliability of the components, e.g., voltage sen
28、sitive devices. 4.2.8PROCEDURE FOR RESISTANCE BUDGET a.Determine entire voltage drop that is acceptable from the positive terminal of the battery to the negative terminal of the battery. b.Divide the voltage drop by the anticipated current draw of the load to calculate the entire resistance that is
29、tolerable (“Resistance Budget“). c.Subtract known resistance values from the budget amount. Suppliers of components should be able to provide component specifications. If not, they can be measured or estimated by considering electrical contact junctions equal to 1 milli-ohms per contact and internal
30、 switch contacts equal to 8 milli-ohms each. d.Divide the remaining resistance by the distance to and from the load. This is the “Maximum Allowable Resistance“. e.Use Table 4 to determine the wire size needed based on resistance. f.If an iron casting or steel frame is used for ground return, that re
31、sistance will have to be calculated and subtracted from the resistance budget before calculating the power source wire size. 4.2.9Consideration must be given to the connectors that have been chosen when determining cable size. In the case where the wire is too large for the connector, there is an ac
32、ceptable alternative. Here, a smaller diameter wire can be used and the electrical load split between two cables with 2 separate connections. Circuit protection for the smaller wire diameters of such split loads must be reconsidered. 4.3Terminals 4.3.1A corrosion-resistant conductive plating is reco
33、mmended. 4.3.2Terminal materials and platings shall be chosen to reduce galvanic corrosion when mated. Low-energy circuits may require terminal materials which prevent degradation due to vibration, fretting, corrosion, and oxidation. TABLE 4TYPICAL 1 V DROPS RUN LENGTHS 0.8123581319Cable Size (mm2)
34、Amperage (amps) 2.59.01322345484135182 54.56.6111727426891 7.53.04.47.31118284561 102.33.35.48.514213445 12.52.64.46.811172736 153.65.79.0142330 202.74.36.8111723 253.45.48.41418 302.84.57.01115 MarginalAcceptable SAE J1614 Issued MAR1998 -6- 4.3.3All terminations shall conform to the physical and e
35、lectrical performance requirements of SAE J163, except that the voltage drop test is to be modified as follows: a.200 off/on cycles at 125 C 3 C, 60 min off at 21 C 2 C. b.Transition between temperature states to occur at 3 C per min with the power off during the transition. Terminals shall meet the
36、 contact resistance test after cycling. 4.3.4Contact resistance measurement of connection resistance as illustrated in Figure 2. The resistance of the cables shall be subtracted from measured values. FIGURE 2CONTACT RESISTANCE TEST POINTS 4.3.5Measurements at specified test current shall be taken af
37、ter thermal equilibrium at current levels shown in Table 5. TABLE 5CONTACT RESISTANCE TEST CURRENTS Cable Size (Ref. J163) (mm2) Test Current (A) 0.810 115 220 330 540 850 1360 1970 +3 C 0 C - - SAE J1614 Issued MAR1998 -7- 4.3.6Acceptance criteria of connection resistance is: 10 milli-ohms maximum
38、initially. 20 milli-ohms maximum after endurance testing. 4.3.7Maximum allowable voltage drop across a terminal as depicted in Figure 2 shall be 100 mV. 4.3.8Terminals shall be used and applied according to manufacturers specifications. Special consideration shall be given to terminals carrying low-
39、voltage signals. 4.3.9Terminals shall have cable insulation support or the connector body/device shall provide support for the cable. 4.4Connector Selection 4.4.1Single connections shall be used in close proximity to each other only where there is no possibility of mis- connection in assembly or ser
40、vice. 4.4.2Connector bodies shall be used at all points where two or more cables terminate, and where there is a possibility of mis-connection in fabrication, assembly or service. 4.4.3Cable-to-cable connectors shall have positive locking devices. The locking device shall withstand a pulling force d
41、efined by 111 N times the number of contacts or a maximum of 444 N. The load shall be applied for 30 s. 4.4.4Connectors shall be polarized. 4.4.5Minimum terminal retention, within the connector, shall be 111 N. 4.4.6Secondary locks for the terminal and/or connector are highly recommended. 4.4.7Conne
42、ctors exposed to the outside environment require adequate protection from hazards (brush snags, rock impact, splash proof, etc.) associated with that environment. 4.5Splicing 4.5.1When splices are required, they shall be located dimensionally on drawings to preclude being located: a.In areas of harn
43、ess flexing b.Within 50 mm of a clamp c.Within 50 mm of a branch of the harness d.Within 25 mm of any other adjacent splice e.Within 100 mm of any connector or termination f.Within 150 mm between connected/consecutive splices 4.5.2Configure splice so that a.Cables are not doubled back within the har
44、ness bundle. b.Splices are within the covered or bundled section of the harness. c.The cross sectional area of the cables on either side of the splice are approximately equal. 4.5.3SPLICE CONSTRUCTIONThe cable conductors shall be reliably terminated. All splices shall conform with the electrical spe
45、cifications for splices per SAE J163. Additionally, the splices must meet or exceed the minimum pull test as shown in Table 6 (Extracted from SAE J378). Value to be based upon smallest cable in splice. SAE J1614 Issued MAR1998 -8- 4.6Harness Assembly Construction 4.6.1Cables shall be grouped, where
46、practical, into harnesses. 4.6.2Harness covering shall be selected in accordance with the application. Examples of typical harness coverings are as follows: polyvinyl chloride tape, extruded plastic (PVC) tubing, flexible thermoplastic conduit (typically slit lengthwise), metal conduit, braid (vinyl
47、/nylon or vinyl/polypropylene). 4.6.3The wiring harness covering shall be adequate to protect the harness in the expected environment and shall furnish protection during machine assembly and operation. 4.7Cable Circuit Identification 4.7.1Circuits shall be identified with either color, numbers, lett
48、ers, symbols, or a combination thereof. Identification shall change when passing through an electrical component, but not when passing through a terminal block, connector, splice, or common junction. 4.7.2IDENTIFICATION DURABILITY REQUIREMENTS 4.7.2.1Abrasion Resistance TestPlace the cable on a firm
49、 surface with the circuit identification markings face up. Secure the cable in place. With a force of 30 N, wipe a “Pink Pearl“ or equivalent eraser across the cable and markings parallel to the centerline ten times. 4.7.2.2Fluid Resistance TestImmerse a 200 mm length of cable in 25 C 5 C fluid for 10 min. Remove and wipe the insulation two times with slight pressure using a paper towel. The fluids required for this test are: diesel fuel, gear and engine oil, antifreeze fluid, hydraul