QC/T 1037-2016High-voltage cables for road vehicles (English PDF)

4.1 Model

Cable model is compiled according to QC/T 414-2016. See Annex B for major cable models.

4.3 Structure dimensions

Cable specifications and corresponding structural dimensions are given in Annex A.

4.4 Conductor

4.4.1 The conductor is twisted with bare soft round copper wire or tinned soft round copper wire as specified in Table 1.

- 8kV for AC 600V/DC 900V cable;

- 10kV for AC 1000V/DC 1500V cable.

4.7 Shielding layer (for shielded cables)

4.7.1 The shielding layer is woven with bare copper wire or tinned copper wire as shown in Table 1.The weaving density shall be no less than 85%.

4.8 Sheathed layer (for sheathed cable)

4.8.1 The sheathed layer shall be in close contact with the core and easily peeled off from the core without damaging the insulation and shielding.

4.8.2 Allow the addition of spacers between the sheathed layer and the shield.

4.9 Surface mark

4.9.1 Cable surface shall not have obvious cracks, bubbles, impurities and bumps that exceed tolerances.

4.10 Finished cable

4.10.4 Sheathed layer water immersion withstand voltage.

4.10.7 Peeling force / adhesion.

4.10.8 Cyclic bending.

4.10.11 Wear resistance.

4.10.15 Heat shrinkage.

4.10.16 Chemical resistance reagent.

4.10.17 Mark durability.

4.10.1 Ellipticity

Cable ellipticity shall be no more than 8%.

The sheathed layer is immersed in water 50Hz AC withstand voltage (RMS)

test. The sheath of the cable shall be able to withstand 1kV for 30min, rise the voltage to 5kV, and keep it for 5min without breakdown.

The peeling force / adhesion of the insulation / sheath of the finished cable is determined by both supply-demand parties.

The cable shall meet the requirements of 7.3.5 of GB/T 25087 after cyclic bending test.

The outer layer of the cable shall be capable of withstanding the number of scratches specified in Table 4.

After the finished cable has passed the heat shrinkage test.

- The shrinkage of each end of the insulation shall be no more than 2mm;

- The shrinkage of each end of the sheath shall be no more than 4mm.

The cable is tested by chemical resistance reagent, and the insulation/sheath shall not be exposed/shielded after winding. Carry out the withstand voltage test without breakdown. The type of medium for chemical resistance reagent is determined by both supply-demand parties.

After the cable has been tested for durability, it shall comply with the requirements of 11.3.4 of GB/T 25085.

5.1 General

Except for the exit-factory test, all test samples shall be stored at (23 ± 5)°C for at least 16h.

5.3 Inspection of shielding weaving density

Weaving density is calculated by formula (1).

5.5 Conductor DC resistance test

Conduct the test according to 6.1 in GB/T 25085.

5.6 Insulation layer defect inspection

Inspect according to 6.3 in GB/T 25085.

5.7 Sheathed layer defect inspection

Inspect according to 6.3 in GB/T 25085. Make sure that the shield of the cable is grounded in an appropriate manner for the high-pressure spark test device to function properly.

5.11 Insulation volume resistivity test of insulation layer

Conduct the test according to 6.4 in GB/T 25085. For shielded cables, the sheath and shield shall be cleanly removed without damaging the insulation.

5.12 Insulation volume resistivity test of sheathed layer

Conduct the test according to 6.4 in GB/T 25085. When measuring, the shield is connected to the power supply, positive.

5.13 Shielding efficiency test

Conduct the test according to 6.3 in GB/T 25087.

5.14 High temperature pressure test

Conduct the test according to 7.1 in GB/T 25085 for single core unshielded cable. Conduct the test according to 7.1 in GB/T 25087 for shielded cable.

5.15 Peeling force/adhesion test

Conduct the test according to 7.2 in GB/T 25085 for single core unshielded cable. Conduct the test according to 7.2 in GB/T 25087 for shielded cable.

5.22 Thermal overload test

Conduct the test according to 10.3 in GB/T 25085 for single core unshielded cable. Conduct the test according to 10.3 in GB/T 25087 for shielded cable.

5.24.2 Specimen

Prepare a sample for a single test. Take insulation and sheath that are 600mm long and are stripped by 25mm long at each end. They are bent into "U" shape around a circular shaft with a diameter of 50mm. The stripped ends are machined into hooks so that the specimen can be hung on the grid of the aging box. The number of specimens to be prepared is shown in Table 5.

6.1 General

The product is tested according to Table 6 (single-core unshielded cable) or

Table 7 (shielded cable). In addition to process testing, samples from the first and periodic tests must be sampled from products that pass the process inspection.

6.2 First trial

All performances of the product shall be inspected. The first trail is only carried out once. Unless there is a major change in the structure and materials of the product, no need to repeat.

6.4 Process test

It shall be sampled by batch or continuously. The number of samples shall be no less than 10%, or no less than 3 pieces.

7.1 Packaging

7.1.1 The finished cable shall be properly packaged in shafts, loops or in barrels so as to accommodate transport and delivery. The number of packages is 50 m or an integral multiple thereof.

7.1.4 Joints and defects shall be clearly marked. Allow removal of 30mm to 100mm insulation as a mark.

7.2 Packaging mark

Each packaging unit shall be labeled. The label shall at least mark the following