qct29106-2004标准（英文版）

QC/T 29106-2004ForewordThis Standard is a revised version of QC/T 29106-1992 “The Technical Conditions of Low Voltage Wiring Harnesses for Automobile”. During its revision, the automotive industry standards of other countries including Germany, France and South Korea are adopted as the main reference standards. This Standard shall take the place of QC/T 29106-1992 as from its effective date.Major differences between this Standard and QC/T 29106-1992 include: -Quoted Standards GB/T 13527.2, HG 2196, QB/T 2423 and QC/T 238 are added.-In the section of Terms and Definitions, “desiccation bound”, “damp bound” and “SKT” are added, and the provisions corresponding to them are also added in the technical requirements.-Technical requirements for pressure welding juncture cross-sections are added.-Specifications for nominal conductor cross-sectional areas and their corresponding tensile forces are added.-Technical requirements for pressure welding of sealing plugs are added.-Modifications are made to the wiring harnesses ambient temperature range, anti-high/low temperature property, heat-humidity resistance, anti-vibration performance, salt-fog resistance and their corresponding testing methods.-Requirements of temperature variation resistance are added.-Requirements of industrial solvent resistance substitute for those of oil repellency.- “Juncture water proofing”, “tearing force of solderless welding joints” and “sealing plug pressure welding” are added in the items for exfactory inspection.- Modifications are also made to the sampling methods, grouping, inspection items and inspection orders of type inspections.This Standard is proposed by China Association of Automobile Manufactures. This Standard is under the management of National Automotive Standardization Technical Committee.This Standard is drafted by Changchun Bulb and Electric Wire Co., Ltd. Main drafters: Sun Yude, Tang Manru, Fang Xingya, Jiang Shusen, Zhang Jie and Qian Cheng.The Technical Conditions of Low Voltage Wiring Harnesses for Automobile1 ScopeThis Standard specifies the requirements, inspection methods, inspection rules, marking, packaging, storage and caretaking of low voltage wiring harnesses for automobile (hereafter referred to as wiring harnesses).This Standard suits various wiring harnesses (single wire included) for automobile of nominal voltage lower than 50V.2 Cited Normative DocumentsAs employed by this Standard, the clauses of the following documents have become the clauses of this Standards. All the amendment slips from the employed documents (excluding corrections of errors in content), or revised versions which have arisen after the dates printed therein shall not be applicable to this Standard. Nevertheless, the various parties involving the commitment of this Standard are encouraged to examine whether the latest versions of these documents shall be used. The employed documents with no date printed therein shall have their latest version applied to this Standard.GB/T 2828.1-2003Sampling procedures for inspection by attributes - Part 1: Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-lot inspectionGB 11121Gasoline engine oilGB 17930Lead-free gasoline for automobilesGB/T 13527.2Plasticized polyvinyl chloride tubing (for electrical insulation)HG/T 2196Rubber materials for motor vehiclesJB/T6313.1General specifications for electrical braided brass wireJB/T 6313.2Electrical brass wires twill braided wireJB/T6313.1Electrical brass wires straight braided wireJB/T 8139Road vehicles low voltage cables (wires)JJG4Steel tape rulerQB/T 2423PVC pressure sensitive electrical insulating tapeQC/T 238Storage and caretaking of automobile spare partsQC/T 413-2002Basic technical requirements for automotive electrical equipmentQC/T 414Colours of low voltage automotive wiresQC/T 417.1Vehicle wiring harnesses connectors, Part 1: Definitions, tests and general performance requirements (Automobile)QC/T 417.3Vehicle wiring harnesses connectors, Part 3: Sizes and special requirements for single-strand flat connector clipsQC/T 417.4Vehicle wiring harnesses connectors, Part 4: Sizes and special requirements for multi-strand flat connector clips QC/T 417.5Vehicle wiring harnesses connectors, Part 5: Sizes and special requirements of cylindrical connector clips for single/multi-strand connectorsQC/T 29010Types, sizes and technical requirements of low voltage automotive wire terminalsQC/T 29013Types, sizes and technical requirements of automotive battery wire terminals3Terms and DefinitionsThis Standard employs the definitions prescribed hereafter and in QC/T 417.1.3.1 main stem The part of the wiring harness where two or more wires are bound together. Location number of jacketWire numberMain stemEmbranchment pointLateralJunctureFigure 13.2 Lateral The unbound wire ends of the wiring harness or single wire (See Figure 1)3.3 Embranchment point The intersection point of one main stem and another main stem or a main stem and a lateral in the wiring harness (See Figure 1).3.4 Juncture The joint of electric wires (See Figure 1)3.5 Terminal A general term for connector clips and joints.3.6 Desiccation bound The sector of the wiring harness installed in the driving cab, passengers compartment, luggage compartment and so on where no special water-proof processing is needed.3.7 Damp bound The sector of the electric wire harness other than desiccation bounds where special water proof processing is needed.3.8 SKT A connecting way in which the terminal punctures the electric wire insulating lamination to connect it with the electric wire conductor and makes good electrical contact with certain anti-tension force. 4Requirements4.1The electric wiring harnesses shall comply with the requirements of this Standard, and manufactured according to the drawings and technical files permitted by specified procedures.4.2The electric wiring harness sizes shall comply with the following requirements:4.2.1The lengths of main stem and protective jacket shall be no less than 100 mm and be multiplied instances of 10.For example, 100 mm, 110 mm, 120 mm, etc.4.2.2 The length of the lateral shall be no less than 30 mm.4.2.3The distances between juncture and juncture, juncture and embranchment point shall be no less than 20 mm.4.2.4When the insulating sleeve needs to be fitted between the electric wire and the terminal, the insulation jacket shall be no shorter than 20 mm.4.2.5The wiring harness limit deviation of basic sizes shall comply with the specifications in Table 1.4.3Unless other specified, the materials and spare parts used in the wiring harness should comply with the following requirements. 4.3.1Priority shall be given to the electric wire colours as specified in QC/T 414.4.3.2The junctures shall comply with the specifications of QC/T 29010 and QC/T 29013.4.3.3Connectors shall comply with the specifications of QC/T 417.1, QC/T 417.3, QC/T 417.4, QC/T 417.5.Table 1 Limit Deviation of Basic Sizes mm Limit DeviationBasic Sizes of Wiring HarnessMain StemJunctureProtective Jacket4.3.4The electric wire shall comply with the specifications of JB/T 8139, and the braided brass wire shall comply with the specifications of JB/T 6313.1, JB/T 6313.2, JB/T 6313.3.4.3.5Plasticized polyvinyl chloride tubing shall comply with the specifications of GB/T 13527.2.4.3.6The materials in rubber products shall comply with the specifications of HG/T 2196.4.3.7PVC pressure sensitive insulating tapes shall comply with the specifications of QB/T 2423.4.4Priority shall be given to pressure welding when connecting terminals with electric wires, and the connection shall comply with the following requirements:4.4.1 The terminals shall be tightly pressed against the conductors and insulating laminations without breaking the conductors, and the insulating laminations shall not be pressed into the pressure welding sectors of the conductors. As shown in Figure 2, the electric wire conductor in area “a” is visible, but it does affect connecting. 4.4.2 After no less than 3 cycles of bending tests, the pressure welded insulating lamination in area “b” of Figure 2 is still visible.TerminalElectric wirePressure welded part of the conductorPressure welded part of the insulating laminationFigure 24.4.3The cross-sections of the terminals and electric wire pressure welding parts involved in pressure welding shall comply with the specifications of Annex A.4.4.4When soldering, no erosive flux is allowed, and the welding spot shall be smooth without any defect like missing welding, incomplete welding or welding flux inclusion.4.4.5The terminal and the electric wire shall be fitted securely with tensile forces no less than those specified in Table 2 and will not be impaired or broken apart under specified tensile forces.4.4.6The SKT method shall be performed in compliance with the following requirements:4.4.6.1The electric wire end planes shall be even and perpendicular to the axes of the wires, and the conductors and insulating laminations at the end planes shall be in the same plane. The electric wires at the connecting parts shall not be bent, and the ends of the electric wires shall be visible in area “a” of Figure 3. 4.4.6.2 The terminal and the electric wire shall be fitted securely and will not be impaired or broken apart under specified tensile forces. The tensile force of 0.35 mm2 electric wire shall be no less than 50N.Figure 2Tensile ForceNominal conductor cross-sectional area, mm2Tensile Force1), NNominal cross-sectional area of conductor, mm2Tensile Force, N0.50506.004500.758010.005001.0010016.0015001.5015025.0019002.5020035.0022004.0027050.00120.0027001) When a juncture or terminal connects two or more electric wires at the same times, choose the wire with larger cross-sectional area to test the tensile force.TerminalPunctured spotElectric wirePunctured spotFigure 34.4.7 The voltage drops at the junctures of the terminals and electric wires shall be no larger than those specified in Table 3.Table 3 Voltage DropsNominal conductor cross-sectional area, mm2Testing currency, AVoltage Drop, mVNominal conductor cross-sectional area, mm2Testing currency, AVoltage Drop, mV0.505310.0050250.7510516.0060151.0015825.0070181.50201135.0080202.50151650.0090234.00201870.00100256.003020-4.5The junctures shall comply with the following requirements4.5.1In pressure welding, the conductor shall not be broken, and the cross-sections of the junctures shall comply with the specifications of Annex A.4.5.2 When soldering, no erosive flux is allowed, and the welding spot shall be smooth without any defect like missing welding, incomplete welding or welding flux inclusion.4.5.3 For solderless welding, the welding surface shall not develop oxidation, wire break, defect and insulating lamination fusion. As shown in Figure 4, the transition sector “a” between welded and un-welded parts shall be arc-shaped, and the un-welded conductor end shall be visible in sector “b”. Figure 44.5.4The junctures shall be secure and not be impaired or broken apart under specified tensile forces, which shall be no less than those specified in Table 2. When solderless welding is employed, the tearing force shall be no less than those specified in Table 4.Table 4 Tearing ForceNominal cross-sectional area of conductor,mm2Tearing Force1), N0.50150.75231.00351.50452.50704.001006.001301) Choose the wire of smaller cross-sectional area to test the tearing force.4.5.5 The juncture surface insulation between the desiccation bound and damp bound shall be good, and the insulation material shall press tightly against the juncture free of displacement and detachment. 4.5.6After water-proof testing, the insulation resistance at the insulation treated part of the damp bound juncture shall not be lower than 100 M.4.6The sealing plug shall not be damaged in press welding, and there shall be no visible clearance between the wire and the sealing plug, the sealing plug and the jacket. When the electric wire and sealing plug are pressure welded with the terminal, the ends of the sealing plug and the electric wire insulating lamination shall be visible in area “a” of Figure 5. Electric wire insulation laminationSealing plug endElectric wireTerminalSealing plug4.7When binding the electric wire harness, make it tight and even. When the protective jacket is used, no displacement or bending that affects the wiring harness is allowed. 4.8 The insulating sleeve at the joint of the electric wire and terminal in the wiring harness shall tightly wrap the juncture free of displacement and detachment.4.9 The electric wire in the wiring harness and the spare parts shall be assembled properly free of dislocation, and the terminal shall not slip out of the protective jacket.4.10 Continuity in the wiring harness shall be 100%, free of short circuit or misrouting. 4.11 The temperature variation resistance of the wiring harness shall comply with the following requirements: 4.11.1 The wiring harnesses shall be assembled according to Table 5, and after anti-low temperature property testing, they shall comply with the specifications in 4.7, 4.8, 4.10 of this standard.Table 5 Operating temperature and Storing temperature ()ItemsInstallation PositionWiring Harness on the EngineWiring Harness under the Engine HoodWiring Harness at Other PositionsMinimum Operating Temperature-40Minimum Storing Temperature-40Maximum Operating Temperature1208565Maximum Storing Temperature13095754.11.2The wiring harnesses shall be assembled according to Table 5, and after anti-high temperature property testing, they shall comply with the specifications in 4.7, 4.8, 4.10 of this standard.4.11.3The wiring harnesses shall be assembled according to Table 5, and after temperature variation resistance testing according to 3.10.3 of QC/T 413, they shall comply with the specifications in 4.7, 4.8, 4.10 of this standard.4. 12 After temperature/humidity cyclic variation resistance testing according to 3.11 of QC/T 413, the wiring harnesses shall comply with the specifications in 4.7, 4.8, 4.10 of this standard.4.13 After anti-vibration performance testing according to 3.12 of QC/T 413, the wiring harnesses shall comply with the specifications in 4.7, 4.8 4.9, and 4.10 of this standard.4.14 After 48h salt-fog resistance testing according to 3.13 of QC/T 413, the wiring harnesses shall comply with the specifications in 4.10 of this standard.4.15 The wiring harnesses shall go through industrial solvent resistance testing, and the recommended solvents include Glass Cleaner Concentrate, Lead-free gasoline for automobiles and Gasoline engine oil, and the tested wiring harnesses shall comply with the specifications in 4.7, 4.8, 4.10 of this standard.5Test Procedure5.1 Unless otherwise specified, the actual test procedure shall be performed after stabilizing for 2 hours under the following conditions：Ambient temperature range：1828Relative air humidity：45%75%Air pressure：86 kPa106 kPa5.2 The wiring harnesses shall be measured with steel tape ruler and comply the specifications of 4.2.5.3 Eye test the wiring harness appearance to make sure it comply with the specifications of 4.4.1, 4.4.3, 4.4.6.1, 4.5.2, 4.5.3, 4.5.5, 4.6, 4.7, 4.8 and 4.9.5.4 Perform bending test on the pressure welding part of the insulating lamination as shown in Figure 2. Bend it 300 times with the axis as a benchmark, and 600 times in the opposite direction, and then return to the axis and a cycle is complete.5.5 Testing of tensile force and tearing force in connections of electric wire and terminal, SKT and junctures shall be performed with the tensile testing machine of relative indicating value error no larger than 1, and the tensile testing machine chuck shall move constantly at a speed of 25 mm/min100 mm/min.5.5.1 The tensile force for testing of connections between electric wire and terminal, SKT and junctures shall be applied in the direction of the electric wire axis. 5.5.2 Tearing force testing of solderless welding junctures shall be performed as shown in Figure 6.Force directionFixing pointFigure 65.6 Testing of the terminal and conductor pressure welding and the cross-section of pressure welding juncture shall be performed in the following methods.5.6.1 For preparation of the testing sample, the testing sample shall be truncated according to the positions shown in Figure 7 (avoiding the terminal stiffening ribs), grind one side of it and perform chemical corrosion treatment of it till the section condition is completely shown. Truncated positionElectric wireTerminalFigure 75.6.2 Sample testing: Observe the prepared sample section with microscope and test it according to the requirements in Annex A.5.7Testing of the voltage drop at the pressure welding part of terminal and electric wire shall be performed according to Figure 8. First test the voltage drop from the middle point of the pressure welding sector of terminal and electric wire to 75mm of the electric wire (peel the insulating lamination and solder it securely), and then the voltage drop at the pressure welding part can be gained by subtracting the voltage drop of the 75 mm electric wire. When a terminal is connected with two or more electric wires, the voltage drop of each electric wire shall be tested with electric currents.Testing pointFigure 85.8Pe