DESIGN STANDARDS

Design Standards
Selection of Cable Sizes and Cable types

1.0 Title Selection of Cable types & sizes for designing of a Wiring Harness 2.0 Purpose To provide guideline for selection of various types & sizes of cable for designing of wiring harness

DESIGN STANDARDS

3.0 Application It is applicable for designing of wire type and sizes for all types of wiring harness. 4.0 Guidelines: The Cable types are decided considering the following key parameter requirements. Flexibility. Heat resistance. Core construction. Purpose of the circuit (Power, signal) Wiring harness weight and diameter. Space availability in the vehicle. 4.1 Cable type selection: Flexibility: Various wire types are available in relation with its flexibility characteristics. Flexibility is achieved by keeping the conductor diameter less. Higher flexibility ensures no breakage of conductors and wires during the actual usage. Where flexibility / volume/space restriction/weight is an issue, generally a thin walled cable would be preferred. S. No. 1 2 3 4 Wire type Available wire sizes Conductor Flexibility Less Less Very High High

diameter (mm) AV and AVS 0.5, 0.85, 1.25, 2.00, 3.00 0.32 AV AVF CPAVS AVSS & 5.00 8.00, 10.00 & 15.00 and 0.5, 0.75, 1.25 & 2.00 0.3 0.5 0.85 1.25 Available wire sizes 0.45 0.20 & 0.26(2.0) 0.26 0.32 0.24 0.29 Conductor diameter (mm)

S. No.

Wire type

Flexibility

DESIGN STANDARDS 5 AVSSF 0.3 0.5 0.75 1.25 2.00 0.5 0.75 1.0 1.5 2.5 4.0 6.0 0.5 1.0 1.5 2.5 4.0 6.0 0.16 0.19 0.23 0.21 0.26 0.195 0.195 0.195 0.244 0.260 0.310 0.310 Very High

FLRY/ FLRYw

Highly flexible with reduce outer diameter due to reduced PVC thickness and smaller strands diameter. Less flexible due to thicker PVC covering

FLY/ FLYw

S. No. Application Flexibility recommendation 1 Doors, Two wheelers, Moving Parts Very High 2 Instrument console, Roof High 3 Floor, Engine compartment Less Select the cable type according to the application requirements by using the above given data. 4.2 Heat-Resistance: It is a very important characteristic and it must be taken while designing. The current carrying capacity of wires becomes less when it passes through the heat zone of the vehicle. To maintain the current carrying capacity and cross-section of the wires the heat resistance wires can be used. S. No. 1 2 3 4 5 Wire Type AV(f), Heat resistance category AVS(f), 80 C 100 C 100 C 120 C 120 C PVC Insulation Irradiate cross linked vinyl Insulation Heat resistant vinyl Insulation Irradiate cross linked polyethylene Insulation. Irradiate cross Insulation. linked polyethylene AVSS(f), AVX, AVSSX AVSSH AESSX AEX Features

DESIGN STANDARDS Tinned 6 FLY -20 C~100 C annealed copper stranded

conductors. Insulation & sheath compound for general automotive cables with max. for max. temp. flexible temp. bearing at 140 C Insulation compound automotive cables with

FLRY

-25 C~110 C

FLYw / FLRYw

-35 C~120 C

bearing at 150 C Insulation & sheath compound for large temperature cold flexible. range with max. temp. bearing at 140 C and heat aging resistant,

Note: Heat resistance category expresses the maximum allowable conductor temperature using a guidance of 10,000 hours of accumulated conducting time. Heat resistance category = ambient temperature + increase in temp due to passing the load current in the wire. Select the cable according to the Heat zone by using the above given data. 4.3 Wire construction:

According to the locations and number of wires passing the various type of wire construction can be selected. S. No. 1 2 Location or Purpose of wiring harness passing As a bunch of wires two ends) 3 Three wires in flat condition (No joints in between Three flat wire two ends) 4 Battery cables EB Wires Recommended wire Single core type

Two wires in flat condition (No joints in between Twin flat wire

DESIGN STANDARDS 5 6 Noise suppressor for reducing the radio Braided Cable/ Twin cable FLCEX/TAC with XTV tubes

interferences/RFI/EMI Fusible link

Safety critical cables

Mantle cables

In the circuits which need to protected from the interference of outside electronic signals must be protected by shielded cables. The shielded cable construction to be selected based on the circuitry requirements. Example: a. Number of core inside the shield. b. Cross-section of the wires. c. Type of the core. In the circuits pertaining to speaker connection, ATW (Twisted wires) can be selected. Select the cables for the specific usage by using the above given data. 4.4 Wiring harness weight and diameter:

In a wiring harness reducing the weight and diameter of the product is very important. According to the requirement various kind of wires can be selected. The different categories are as follows. S. No. 1 2 3 4 Type of Wires AV, AVF AVS, AEX, AVX, FLY, FLYw AVSS, AVSSH, AVSSX, AESSX, FLRY, FLRYw CAVUS Property Ordinary Slim Super-Slim. Ultra-Slim

The thickness of the insulation reduced in slim cables. The thickness further reduced in superslim wires. 5 5.1 Cable Type Selection Life of the Product:

DESIGN STANDARDS Prior to selection of the wire sizes, the life of the product must be decided. Based on that various parameters are considered for designing. 5.2 Accumulated Current Energized Hours: According to life of the product, the accumulated current energized hours are decided. For Example: On the assumption that an automobile is used for 10 years at a service rate of 3 hours a day and 333 days a year, the accumulated current energized hour is set for 10,000 hours. 5.3 Permissible temperature of Conductor: In determining the permissible current, the permissible temperature of the conductor is extremely essential. The Permissible temperature is the value at which the insulator will come unusable due to thermal deterioration within its expected service life. For reference the heat-resistivity deteriorated life characteristics curve is shown in explanatory figure.1 5.4 Permissible Current: The calculation formula for the permissible current of cable shall be as follows. I2r = (T1-T2)/R Where, I = Permissible current of Cable in Amp. r =Resistance of cable conductor (Ohm/Cm) T1=Maximum Working temperature of Conductor (C) T2=Ambient Temperature (C) R =Heat resistance (C/W/cm) While, conductor resistance rT1 at T1 C is, rT1 = r20 {1+0.00393 (T1 20)} Where, r20: Resistance of cables conductor at 20C. For the above value, the following stipulated resistance values of the conductors are used respectively: (JIS C 3406 for AV, JASO D 611 for AVS and JASO D 608 for AVX and AEX.) The heat resistance of R is given by R = R1 + R2 Where R1 = Heat resistance of the insulator.

DESIGN STANDARDS R2 = Surface Heat radiation resistance. R1 = (P1/2 ) loge (d2/d1) Where P1 = Specific Heat resistance (C/W/Cm3) ( 600 for Vinyl and 450 for Polyethylene) d1 = Outer diameter of conductor in mm. d2 = Outer diameter of Insulation in mm Surface heat radiation resistance is given by R2 = 10 P2 / d2 Where P2 = Specific surface heat radiation resistance of the cable (C/W/Cm3) For d2 <= 12.5 mm P2 = 300 + 32d2 For d2 > 12.5 mm P2 = 700 Example: Assumption: AV 0.85 square mm wire. I r20 T1 T2 d2 d1 = = = = = = Not Known (For 0.85 Square mm) = 20.8 Milliohm/Meter. 80C 50C 2.4 1.2

Calculations: R= R1+R2

DESIGN STANDARDS

R1 = (P1/2 )loge(d2/d1) P1 = 600.(AV wire is made of Vinyl) R1 = (600/2*3.14) loge(2.4/1.2) R1 =28.7608276112084 R2 = 10 P2 / d2 P2 = 300+(32*2.4) = 376.80(P2 is less than 12.5mm) R2 = (10*376.80)/(3.14*2.4) = 500.00 R= R1+R2 = 28.76082716112084 + 500.00 = 528.76082716112084 rT1 = 20.8 * {1+0.00393 * (80 20)} rT1 = 25.704640 Milliohm/mtr = 0.0002570464 Ohm/cm. I2r = (80-50) / 528.76082716112084 I = SQRT {[(80-50) / 528.76082716112084]/0.0002570464} I = 14.86 Amps. Permissible Current of AV 0.85 Square mm when the maximum conductor temperature is 80C and the ambient temperature is 50C is 14.86 Amperes. 5.5 Reduced coefficient of permissible current by bundling the Cables Reduced coefficient is a factor to indicate the decrease in the permissible current compared with the case of a single cable, when the current is energized to cables in bundle, where a reduced heat radiation and the mutual heating among the cables occur. The reduced coefficient of the permissible current by bundling the cables shall as per the Table given below. But this reduced coefficient is only determined by the quantity of the cables, which are energized at the same time, and this does not accord by the total quantity of the cables, which are bundled. Also the cables energized by weak current, which do not contribute to the temperature rise such as the regulating circuit and electronic circuit, are not included in the energizing quantity. Energized quantity of the bundled cables Reduced coefficient 1 1.00 2 0.80 3 0.70 4 0.60 5 0.55 6-7 0.50 8-10 0.45 11-12 0.40

DESIGN STANDARDS

Example: Using the below mentioned table identify the units that will function at the same time. Number of cables that will be energized at that time and pass along with the circuit. From that find out the reduced coefficient on permissible current and multiply with permissible current. Blower Charge circuit Head Lamp A/C Front Wiper
Qty Use Qty

Function

Use

Qty

Use

Qty

Use

Qty

Use

Use

Rear Wiper
Qty

Front wiper is # ON Head lamp is ON #

1 1

# #

1 1

# #

1 0

# #

NA # 1 #

0 0

NA #

5.6 Limited Over current The limited over current with the limit defined as the time when insulator of the cable starts fuming due to temperature rise is derived from the formula given below. Remark: The fuming is defined as when the evaporating of the volatile matters inside the insulator can be visualized due to the temperature rise of the cables, and the judgment of the limited over current shall start with the initial fuming. The fuming temperature of the cables can be considered in the calculation are 140C for AV, 150C for AVS, 170C for AVX, and 190C for AEX. I2r = (T1-T2)/R/ (1-e-at) Where, I : Current of the Cable (A) r : Resistance of cables conductor (Ohm/Cm) T1 : Temperature of the conductor at fuming (C) T2 : Ambient temperature (C) R : Heat resistance (C/W/Cm) A : Reciprocal of thermal time constant T : Time (s) While, the resistance of the conductor rT1 at T1C is given by rT1 = r20 {1+0.00393 (T1-20)} Where, r20 : Resistance of the cables conductor at 20C

For the above value, the following stipulated resistance values of the conductors are used respectively:

DESIGN STANDARDS (JIS C 3406 for AV, JASO D 611 for AVS and JASO D 608 for AVX and AEX.) The heat resistance R is given by, R = R1 + R2 Where, R1 R2 : Heat resistance of the insulator : Surface heat radiation resistance

The specific heat resistance of the insulator is given by, R1 = (P1/2 ) log e (d2/d1) Where, P1 d1 d2 : Specific heat resistance of the insulator (C/W/cm3) (600 for Vinyl and 450 for Polyethylene) : Outer diameter of the conductor (mm) : Outer diameter of the insulator (mm)

The surface heat radiation resistance is given by: R2 = 10P2/ d2 Where P2 = Specific surface heat radiation resistance of the cable (C/W/Cm3) For d2 <= 12.5 mm P2 = 300 + 32d2 For d2 > 12.5 mm P2 = 700 Where, = C.R C W H : Thermal Capacity C = W.H : Mass of each component material (g/cm) : Heat capacity of each component material (J/C.g)

In this case, 0.39 for copper, 1.43 for Vinyl, and 2.3 for polyethylene. a = 1/ = 1/C.R In this case, For vinyl a = 1/R (0.39 Wcu + 1.43 Wpvc) For Polyethylene

DESIGN STANDARDS a = 1/R (0.39 Wcu + 2.3 Wpvc) Example: Assumptions: AV 0.85 Square mm wire. I2r = (T1-T2)/R/(1-e-at) Where, I r T1 T2 t : Not Known : 20.8 Milliohm/Meter : 150C : 50C : 50 Seconds (assumed)

While, the resistance of the conductor rT1 at T1C is given by r150 = 20.8 {1+0.00393 (150-20)} = 31.426720 Ohm/mtr = 0.00031426720 Milliohm/cm The heat resistance R is given by, R = R1 + R2 Where, R1 : Heat resistance of the insulator R2 : Surface heat radiation resistance The specific heat resistance of the insulator is given by, R1 = (P1/2 ) loge (d2/d1) Where, P1 : 600 AV wire is made of Vinyl d1 : 1.2 mm d2 : 2.4 mm R1 = (600/2*3.14) log (2.4/1.2) = 28.7608276112084 The surface heat radiation resistance is given by: R2 = 10P2/ d2 Where P2 = 300 + 32d2 ..(d2 <12.5 mm) P2 = 300 + (32*2.4) = 376.80 R2 = 10 * 376.80 / (3.14 * 2.4) = 500.00 R = 28.7608276112084 + 500.00 = 528.7608276112084 a = 1/R (0.39 Wcu + 1.43 Wpvc)..AV wire is made of Vinyl

DESIGN STANDARDS

a = 1/528.7608276112084 * (0.39 * 0.08 + 1.43 * 0.05) = 0.018983884 I2r = (T1-T2)/R/ (1-e-at) I2= [(150-50)/ 528.7608276112084/ (1-EXP (-0.018983884* 50)]/ 0.00031426720 I = SQRT (981.8) = 31.33 5.7 Permissible Voltage Drop

The choice of cable depends on the current drawn by the consumer. The larger the cable used then the smaller will be the voltage drop in the circuit, but the cable will be heavier. This means a trade off must be sought between allowable voltage drop and maximum cable size. Some typical maximum voltage drops in a circuit is given in the following table. In general, the supply to a component must not be less than 90% of the system supply. Circuit Name Nominal Voltage Lighting Circuit Load <15W Load >15W Charging circuit Starter circuit Starter solenoid Other circuits Permissible voltage drop in positive cable in Volts 12 V 24 V 0.1 0.3 0.5 0.5 1.5 0.5 0.2 0.6 1.0 0.5 1.9 1.5 Permissible voltage drop in complete circuit in Volts 12 V 24 V 0.6 0.6 0.5 1.0 3.0 1.0 1.2 1.2 1.0 1.0 3.8 3.0 Notes

Nominal Load Maximum at 20C Pull-in Load Nominal Load

The voltage drop in a cable can be calculated: Calculate the current: The voltage drop is then: Where: I W Vs V = = = = I=W/Vs V=I l/A

Current in amperes Power rating of components in watts System supply in volts Voltage drop in Volts

DESIGN STANDARDS l A = = = Resistivity of copper in Ohm/square mm per meter. length of the cable in metres Cross sectional area in square mm.