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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: +1 (724) 776-4970 FAX: +1 (724) 776-0790 SAE WEB ADDRESS h
3、ttp:/www.sae.org Copyright 2001 Society of Automotive Engineers, Inc. All rights reserved.Printed in U.S.A. SURFACE VEHICLE 400 Commonwealth Drive, Warrendale, PA 15096-0001 STANDARD J2031 REV. DEC2001 Issued1990-01 Revised2001-12 Superseding J2031 SEP1996 High Tension Ignition Cable 1.ScopeThe spec
4、ifications contained in this SAE Standard pertain to high tension ignition cable used in road vehicle engine ignition systems. 2.References 2.1Applicable PublicationThe following publication forms a part of this specification to the extent specified herein. 2.1.1UL PUBLICATIONAvailable from Underwri
5、ters Laboratories, 333 Pfingsten Road, Northbrook, FL 60062- 2096. UL 1581 2.2Related PublicationsThe following publications are provided for information purposes only and are not required for this document. 2.2.1ASTM PUBLICATIONAvailable from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428
6、-2959. ASTM D 471Standard Test Method for Rubber PropertyEffect of Liquids 2.2.2SAE PUBLICATIONAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001. SAE J2032High Voltage Ignition Cable Assemblies 3.Cable DimensionsThe average overall diameter of finished cable shall be 5 mm, 7 mm,
7、or 8 mm. Other sizes are acceptable and dimensional control for these will be as agreed on by manufacturer and customer. Allowable tolerance for either size shall be 0.3 mm. The average overall diameter shall be determined by taking the average of five sets of measurements along a 1 m length of fini
8、shed cable. Each set of measurements shall consist of the determination of the maximum and minimum diameter at the point of measurement. 4.Test RequirementsWhen tested according to the methods outlined, the ignition cables covered by this document shall be capable of complying with the applicable re
9、quirements specified herein. Test methods and requirements for cable constructions other than those specified previously will be as agreed on by manufacturer and customer. Figure 1 defines the applicability of the test and provides specific performance criteria. NOTEWherever the term “room temperatu
10、re” is used, it shall be defined as 23 C 5 C. SAE J2031 Revised DEC2001 -2- FIGURE 1TEST APPLICABILITY AND PERFORMANCE CRITERIA SAE J2031 Revised DEC2001 -3- 4.1Spark TestWhen agreed upon by the manufacturer and customer, an AC spark test shall be performed on 100% of production of each ignition wir
11、e to which it is applicable (see Figure 1). Apparatus shall consist of a voltage source, electrode, voltmeter, fault-current device or system, and the necessary electrical connections. The recommended apparatus and test method shall be that described in UL 1581, Section 900. Test potential shall be
12、25 kV for 5 mm, 25 kV for 7 mm cable, and 30kV for 7 mm High Energy or 8 mm cable. NOTEThis test is not a qualification test but an in-process test carried out under production conditions. Alternate methods for this test may be considered provided that insulation faults are detected with the same de
13、gree of certainty. 4.2High Potential TestRefer to A.1 in Appendix A for test apparatus. Immerse an approximate 1200 mm specimen for 4 h in a salt solution (3% m/m of NaCl in water) at room temperature with the ends twisted together and emerging approximately 400 mm above the surface of the solution.
14、 Apply a test voltage of 20 kV (rms) for 30 min between the conductor and the solution. NOTEThe applied potential is to be increased from near zero at an essentially uniform rate not to exceed 500 V/s. The cable shall not break down. Then increase the voltage at a rate not exceeding 500 V/s to the f
15、ollowing levels: 5 mm cable25 kV (rms) 7 mm cable30 kV (rms) 7 mm High Energy cable35 kV (rms) 8 mm cable35 kV (rms) Cable breakdown shall not occur below the voltage indicated. 4.3CapacitanceSoak an approximate 1200 mm specimen in a salt solution (3% m/m NaCl in water) at 70 C 2 C for 24 h with eac
16、h end of the cable emerging approximately 100 mm above the surface of the solution. Measure the capacitance between the conductor and the solution. Immerse the same specimen in tap water at 23 C 2 C for 1 h with each end of the cable emerging approximately 100 mm above the surface of the water. Agai
17、n, measure the capacitance between the conductor and the water. The frequency applicable to both measurements shall be 1000 Hz. Measured capacitance values shall not exceed those agreed on between the cable manufacturer and the user. 4.4Corona ResistanceAffix an approximate 1200 mm specimen to a man
18、drel as specified in A.2 in Appendix A. Apply the test potential specified in Figure 1 for a period of 8 h. NOTEThe applied potential is to be increased from near zero at an essentially uniform rate not to exceed 500 V/s. There shall be no breakdown of the cable, nor shall the surface of the specime
19、n exhibit any cracks, fractures, or other defects. 4.5Deformation TestDetermine the average thickness of the covering(s) over the conductor of an approximate 100 mm specimen of finished cable. Mount the specimen into the test apparatus shown in A.3 in Appendix A and load with the following mass: 5 m
20、m cable312 g (include mass of test frame) 7 mm cable450 g (include mass of test frame) 7 mm High Energy cable450 g (include mass of test frame) 8 mm cable510 g (include mass of test frame) SAE J2031 Revised DEC2001 -4- Place the test unit into a full draft, circulating air oven maintained at the tem
21、perature specified in Figure 1 for a period of 4 h. Remove the test unit from the oven and cool within 10 s by immersing in cold water. Remove the specimen and measure the depth of the indentation in the area of the application of the load using an optical device. The value of this measurement shall
22、 not exceed 50% of the original average thickness of the covering(s). 4.6Thermal Overload TestSuspend an approximate 500 mm specimen vertically for 48 h in a full draft, circulating-air oven maintained at the temperature specified in Figure 1. Upon completion of the aging, remove the specimen from t
23、he oven and allow to cool to room temperature. Subject the specimen to winding test as defined in A.4, Appendix A. On completion of the windings, there shall be no evidence of cracks, fractures, or other defects. For resistive cables, measure the resistance of the cable at room temperature before an
24、d after the test. The allowable change in resistance shall not exceed the values specified in Figure 1. 4.7Test for ShrinkageThis test shall apply where shrinkage of the conductor covering(s) is important with respect to the attachment of the connector. Measure the exact length (200 mm minimum) of a
25、 suitable specimen at room temperature. Place the specimen horizontally into a full draft, circulating-air oven maintained at the temperature specified in Figure 1 for a period of 15 min. Remove the specimen, cool to room temperature, and measure the length again. Maximum shrinkage shall not exceed
26、the values shown in Figure 1. In addition, there shall be no evidence of cracks, fractures, or other defects in the surface of the specimen. 4.8Resistance to Flame PropagationFor this test, a Bunsen or Tirrill gas burner having a barrel diameter of approximately 9.0 mm shall be employed. With the ba
27、rrel vertical and the burner well away from the specimen, the height of the flame is to be adjusted to approximately 100 mm. The blue inner cone is to be approximately 50 mm high and the temperature at its tip is to be a minimum of 900 C as measured using a chromel-alumel thermocouple. Suspend an ap
28、proximate 500 mm specimen in a draft-free chamber and expose it to the tip of the inner cone of the flame, as shown in A.5 in Appendix A, for the period of time specified in Figure 1. Any combustion of the specimen must extinguish itself within the time specified in Figure 1 following the removal of
29、 the flame. 4.9Low Temperature TestAffix one end of an approximate 400 mm specimen to a 25 mm rotatable mandrel and attach a 4.5 kg mass to the free end. Subject the specimen, in a vertical position (i.e., with the mass freely hanging), to the temperature specified in Figure 1 for a period of 4 h. W
30、ithout removing the sample from the freezing chamber, wind it a minimum of three turns onto the rotatable mandrel at a speed of one turn/second. There shall be no evidence of cracks, fractures, or other defects. NOTEIf the test device is precooled, a freezing time of 2 h is sufficient. 4.10 Mechanic
31、al Strength TestAn approximate 1200 mm specimen shall be suspended as defined by A.6 in Appendix A and subjected to the following force for a period of 5 min: 5 mm cable180 N 7 mm cable250 N 7 mm High Energy cable250 N 8 mm cable250 N 4.10.1RESISTIVE CABLEFor resistive cables, measure the resistance
32、 prior to the test on the full length of the specimen and again after the test on a 250 mm straight portion of the specimen that was under stress. The change in the resistance per unit length shall not exceed the value shown in Figure 1. 4.10.2REACTIVE CABLEFor reactive cables, verify with approxima
33、tely 12 V DC that there is no discontinuity in a 250 mm straight portion of the specimen that was under stress. SAE J2031 Revised DEC2001 -5- 4.11 Stripping of InsulationWhere cables are required to be stripped, it shall be possible to remove at least 20mm of insulation from the conductor cleanly an
34、d without difficulty. Specific stripping force values, when required, shall be agreed on between the manufacturer and the user. 4.12 Resistance to OilMeasure the diameter of an approximate 400 mm specimen and then immerse for 48 h in ASTM No. 1 oil at a temperature of 90 C 2 C with the cable ends em
35、erging approximately 50 mm above the surface of the oil. (The oil shall be stirred during the test.) Remove the specimen, wipe off the excess oil, and cool to room temperature. The maximum change in diameter shall not exceed 15% nor decrease more than 5%. Subject the specimen to winding test as spec
36、ified in A.4, Appendix A. On completion of the windings, there shall be no evidence of cracks, fractures, or other defects. 4.13 Resistance to FuelMeasure the diameter of an approximate 400 mm specimen and then immerse in ASTM fuel C at room temperature for 30 min with cable ends emerging approximat
37、ely 100 mm above the surface of the fuel. Remove the sample and allow to dry for approximately 30 min. The maximum change in diameter shall not exceed 15% nor decrease more than 5%. Subject the specimen to winding test as specified in A.4, Appendix A. On completion of the windings, there shall be no
38、 evidence of cracks, fractures, or other defects. 4.14 Accelerated Life TestSubject an approximate 1200 mm specimen to winding test as specified in A.4 in Appendix A, and then as specified in A.2. The specimen, while secured to the mandrel, shall then be subjected to each of the five tests outlined
39、in the sequence listed. Test voltages shall be 15 kV (rms) for 5 mm and 7 mm cable and 20 kV (rms) for 7 mm High Energy and 8 mm cable. The test voltage shall be applied for 30 min while the mandrel is contained within a close-fitting, nonmagnetic metallic sleeve, which may have flared ends. Conditi
40、oning prior to the application of the test potential shall be conducted with the sleeve in position. NOTEThe applied potential is to be increased from near zero at an essentially uniform rate not to exceed 500 V/s. The sequence of the high temperature resistance test and low temperature resistance t
41、est may be reversed. When immersed in liquids, the cable ends shall emerge approximately 100 mm above the surface of the liquid. There shall be no breakdown of the test specimen at any point in the sequential testing procedure. 4.14.1RESISTANCE TO SALT WATERPlace the test specimen in a full draft, c
42、irculating-air oven maintained at 90 C 2 C for 4 h and then immediately immerse in a salt solution (3% m/m of NaCl in water) and maintain at 50 C 2 C for 16 h. Remove the specimen from the solution, drain for 30 min at room temperature, and then apply the specified voltage. 4.14.2RESISTANCE TO OILPl
43、ace the test specimen in a full draft, circulating-air oven maintained at 90 C 2 C for 4 h and then immediately immerse in ASTM No. 1 oil and maintain at 90 C 2 C for 16 h. Remove the specimen from the oil, drain for 30 min at room temperature, and then apply the specified voltage. 4.14.3RESISTANCE
44、TO FUELImmerse the test specimen in ASTM fuel C at room temperature for 30 min. Remove the specimen from the fuel, drain for 4 h with or without the sleeve, and then apply the specified voltage with the metallic sleeve in place. 4.14.4HIGH TEMPERATURE RESISTANCEPlace the test specimen in a full draf
45、t, circulating-air oven maintained at the temperature shown in Figure 1 for a period of 48 h. Remove the specimen from the oven, cool to room temperature, and then apply the specified voltage. SAE J2031 Revised DEC2001 -6- 4.14.5LOW TEMPERATURE RESISTANCERemove the nonmagnetic metallic sleeve. Unwin
46、d the test specimen from the mandrel, leaving one end secured, and attach a 4.5 kg mass to the other end. With the mass fully supported by the test specimen, the entire arrangement shall be subjected to the temperature specified in Figure 1 for a period of 4 h. Without removing the specimen from the
47、 freezing chamber, wind it onto the mandrel for five complete turns at the rate of one turn in 5 s. Remove the sample from the freezing chamber, allow it to return to room temperature, remove weight and resecure free end, then replace the nonmagnetic metallic sleeve in place, and apply the specified
48、 voltage. NOTEIf the test device is precooled, a freezing time of 2 h is sufficient. 5.Notes 5.1Marginal IndiciaThe change bar (l) located in the left margin is for the convenience of the user in locating areas where technical revisions have been made to the previous issue of the report. An (R) symb
49、ol to the left of the document title indicates a complete revision of the report. PREPARED BY THE SAE HIGH VOLTAGE IGNITION CABLE TASK FORCE AND APPROVED BY THE SAE IGNITION STANDARDS COMMITTEE SAE J2031 Revised DEC2001 -7- APPENDIX A A.1Test Apparatus for High Potential Test (see 4.2) FIGURE A1TEST APPARATUS FOR HIGH POTENTIAL TEST A.2Test Apparatus for Corona Resistance Test (see 4.4)Winding of the cable: Attach to one end on the cable specimen a mass of 2.5 kg. Fix the free end of the specimen