GB/T 25085.4-2020Road vehicles--Automotive cables - Part 4: Dimensions and requirements for 30 V a. c. or 60 V d. c. single-core aluminium conductor cables (English PDF)

4.1 General test conditions

Should be tested in accordance with the provisions of Table 3 under the test conditions specified in ISO 19642-2.

If both parties agree to modify or change the test methods and requirements, all changes and modifications shall be recorded.

4.2 Safety precautions

The use of this section may involve hazardous materials, operations and equipment. This section is not intended to address possible problems related to the use of this section

All security issues. Users of this section are responsible for formulating appropriate safety regulations and determining the applicability of regulatory restrictions before use.

4.3 Voltage range

The upper limit of the cable voltage in this section is AC 30V and DC 60V.

4.4 Temperature class

The applicable temperature class of the aluminum conductor cable should meet the requirements of Table 1.

Table 1 Rated temperature class

4.5 Conductor material

The conductor shall consist of annealed or annealed compressed aluminum or aluminum alloy monofilaments. The requirements for a single conductor wire shall meet the requirements of Table 2 and

Material specification is completed. The elongation requirements shall be negotiated by the supplier and the buyer. All conductors of the finished cable should meet the resistance requirements of Table 7.

The monofilament of aluminum conductor shall be made of 1000 series aluminum or other alloys specified in EN573-1.The chemical composition should comply with EN573-3.

The requirements of Table 1 in.2013.

Note 1.See Appendix A for examples of twisted structures.

Note 2.The monofilament material and chemical composition of aluminum conductor can also refer to GB/T 16474-2011 and GB/T 3190-2008.

Table 2 Single filament characteristics after annealing

4.6 Conductor

The conductor of the finished cable should meet the requirements of cross-sectional area (CSA) and resistance in Table 7.

The maximum diameter of the conductor should meet the requirements of Table 8.

The stranded structure of the conductor is not a normative requirement.

Note 1.The existing stranded structure of aluminum conductors is shown in Table A.1.

Note 2.The recommended stranded structure of aluminum conductors is shown in Table A.2.

Other twisted structures shall be negotiated between the supplier and the buyer, but they shall meet the above requirements.

4.7 Insulation thickness

This section specifies the following three different insulation thicknesses.

4.8 Cable outer diameter

The outer diameter of each conductor specification and insulation thickness of the cable should meet the requirements of Table 8.

4.9 Representative conductor specifications for testing

When a test is required, all combinations of conductor specifications, insulation thickness and insulation materials should meet the corresponding regulations.

However, when the supplier and the buyer negotiate to allow testing of representative specifications, only the larger and smaller conductor specifications can be tested to prove the cable

The conformity of the family.

4.10 Test items and requirements

Refer to Table 3 for relevant test items applicable to single-core cables in ISO 19642-2.2019.

Table 3 Test items

5.1 General

The cable shall be tested according to ISO 19642-2 according to its rated temperature class.

The cable should be tested in accordance with Table 3.

5.2 Dimension check

5.2.1 Cable outer diameter

The measured value of the cable outer diameter should be within the limit specified in Table 8.

5.2.2 Insulation thickness

The measured value of the insulation thickness shall not be less than the minimum value specified in Table 8.

5.2.3 Conductor diameter

The measured conductor diameter should not be greater than the maximum value specified in Table 8.

5.2.4 Cross-sectional area (CSA)

The measured cross-sectional area should be within the limits specified in Table 7.

5.2.5 Cable outer diameter during manufacturing

The outer diameter of the cable during the manufacturing process shall be continuously monitored.

The measured value of the cable outer diameter during the manufacturing process should be within the limits specified in Table 8.

5.3 Electrical performance test

5.3.1 Conductor resistance

The measured value of conductor resistance should not be greater than the maximum value specified in Table 7.

5.3.2 Requirements for temperature coefficient measurement

For aluminum, alpharho=4.03x10-3K-1.

For aluminum alloys, alpharho should be measured in accordance with 5.2.2 of ISO 19642-2.2019.

5.3.3 Withstand voltage

Apply a voltage of 1kV and apply a time of 30min, and the insulation should not be broken down.

Note. No need to climb voltage.

5.3.4 Withstand voltage after environmental test

Apply a voltage of 1kV and apply a time of 1min, and the insulation should not be broken down.

5.3.5 Insulation defect

Continuous application of 3kV AC voltage, the insulation should not be broken down.

5.3.6 Insulation volume resistivity

Insulation volume resistivity should not be less than 1x109ohm.mm.

5.4 Mechanical performance test

5.4.1 Peel force

The measuring force should be within the negotiated value range between the supplier and the buyer.

5.4.2 Wear resistance

5.4.2.1 General

The test is only applicable to cables with conductor specifications not greater than 6mm2, and either drag or scrape test should be carried out.

Both the supplier and the demander should clarify which test to use.

Cables with conductor specifications greater than 6mm2 need not be subjected to abrasion test.

5.4.2.2 Drag test

The cable sample shall be tested after adding a heavy object according to the requirements of Table 4.

The average value of 4 readings of the cable sample should not be less than the specified value in Table 4.

Table 4 Dragging test requirements

5.4.2.3 Scraping test

The cable sample shall be subjected to the total vertical force as specified in Table 5.

The minimum number of cycles should not be less than the specified value in Table 5.

Table 5 Scratch test requirements

5.4.3 Breaking force of finished cable

The cable specification and breaking force to be tested shall be negotiated between the supplier and the buyer.

5.4.4 Loop bending

The test is only applicable to cables with conductor specifications not greater than 25mm2.

The requirements of the test shall be negotiated between the supplier and the buyer.

5.4.5 Flexibility test

The test is applicable to cables with conductor specifications not less than 8mm2.

The requirements of the test shall be negotiated between the supplier and the buyer.

5.5 Environmental test

5.5.1 Sample preparation and winding test

ISO 19642-2.2019 5.4.1 specifies the size of the mandrel used to prepare the sample in the environmental test.

It also specifies the requirements for winding tests to detect defects caused by environmental stress.

5.5.2 3000h long-term thermal aging under rated temperature class

The sample should be aged for 3000h at the upper limit temperature of the rated temperature class.

After the sample is wound, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.3 Rated temperature class plus 240h short-term thermal aging at 25 degrees C

The sample should be aged for 240h at the upper limit temperature of the rated temperature class plus 25 degrees C.

After the sample is wound, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.4 Rated temperature class plus 6h thermal overload at 50 degrees C

The sample should be aged for 6h at the upper limit temperature of the rated temperature class plus 50 degrees C.

After the sample is wound, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.5 High temperature pressure test

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.6 Heat shrink

The maximum shrinkage of either end of the specimen should not exceed 2mm.

5.5.7 Low temperature winding

The sample should be placed at the lower limit temperature of the rated temperature class for 4h.

After the sample is wound, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.8 Cold shock

The sample should be tested according to the weight of the weight required in Table 6.

After the sample is impacted, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

Table 6 Cold shock test requirements

5.5.9 Alternating temperature and humidity

After the sample is wound, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.10 Hot water

Connect the sample conductor to the "" pole and the copper electrode to the "-" pole for testing.

Use a new sample, change the polarity and retry the test.

For both samples, the insulation volume resistivity should not be less than 1x109ohm.mm.

Visually inspect the insulation for cracks.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.11 Resistant to liquid chemicals

The sample is wound after being impregnated with liquid chemicals, and the conductor should not be exposed after winding.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.12 Cable mark durability

All cable markings should be kept clear.

5.5.13 Stress crack resistance

The test is applied to the use of insulating materials that are susceptible to environmental stress cracking problems (such as FEP and ETFE, and the conductor size is less than

For cables of 6mm2), whether to carry out the test is negotiated by both parties.

After the sample is tested, the conductor should not be exposed.

During the withstand voltage (5.3.4) of the sample after the environmental test, the insulation shall not be broken down.

5.5.14 Ozone resistance

After the sample test, visually inspect the insulation surface to be free of cracks.

5.5.15 Anti-flammability

Any burning flame on the insulating material should be extinguished within 30s after ignition, and the insulation at least 50mm at the top of the sample should remain unburned.

All 5 samples should pass the test.

Table 7 CSA and conductor resistance

Appendix NA

(Informative appendix)

Product model list

The cables are mainly compiled according to QC/T 414-2016.Common types of cables are shown in Table NA.1.

Table NA.1 shows the types of commonly used cables and does not include all types. Negotiated by the supplier and the demander, you can also use

Other types of cables required by QC/T 414-2016.

Table NA.1 List of commonly used AC 30V or DC 60V single-core aluminum conductor cable models

......