汽车电线束技术要求1.范围本标准规定了用于泛亚汽车技术中心有限公司（以下称PATAC）开发的低压线束制造工艺过程技术要求。
按线束的生产流程分，该标准主要分为三部分，分别为开线、预装和总装。
2.术语和定义下列文件对于本标准的应用是必不可少的。
凡是注日期的引用文件，仅注日期的版本适用于本标准。
凡是不注日期的引用文件，其最新版本（包括所有的修改单）适用于本标准。
ISO 8820 保险丝设计规范USCAR 21 美国汽车研究委员会标准21USCAR 38 美国汽车研究委员会标准38QC/T29106-2014 汽车低压电线束技术条件GME 15339 电气功能通用规格标准GMW3172 电子电气部件环境和耐久通用规范GMW3173 ISO导线截面及汽车通讯用导线物理层要求GMW3176 ISO标准的导线规格命名要求GMW3191 接插件测试验证规范GMW3248 扎带规格标准GMW3251 通用紧固件规格标准GMW14124 汽车环境循环测试规范GMW14650 汽车外饰塑料件性能要求GMW14744 橡胶件材料规格标准GMW15267 机电式插头、印刷电路板、线圈式继电器通用规范GMW15608 热缩套管性能要求GMW15626 单芯ISO导线规范GMW15841 连接器及端子设计规范GMW15839 屏蔽及非屏蔽导线规格标准GMW15925 柔性扁平导线测试规范GMW15926 波纹管规格标准GMW16740 胶带规格标准GMW17136 热缩管设计标准3.要求3.1.开线区域3.1.1.开线要求3.1.1.1.尺寸和公差导线开线公差要求，见表1PATAC Confidential表1导线开线长度公差表3.1.1.2.设计标准1)电线原材料符合标准GMW 15626和GMW 15839；2)同轴电缆、水管、USB导线等特殊电线材料，需满足图纸要求；3)断线符合USCAR 21要求。
3.1.1.3.工艺要求，具体如下：1)铜丝不能外露；2)切割须平整；3)绝缘皮不能回缩；4)导线绝缘层完好。
0JIS化学成分(%)标准号C Si Mn P S CuSWRM 60.08 max. 0.60 max. 0.045 max. 0.045 max.SWRM 80.10 max. 0.60 max. 0.045 max. 0.045 max.SWRM 100.08~0.13 0.30~0.60 0.045 max. 0.045 max.SWRM 120.10~0.15 0.30~0.60 0.045 max. 0.045 max.SWRM 150.13~0.18 0.30~0.60 0.045 max. 0.045 max.SWRM 170.15~0.20 0.30~0.60 0.045 max. 0.045 max.SWRM 200.18~0.23 0.30~0.60 0.045 max. 0.045 max.SWRM 220.20~0.25 0.30~0.60 0.045 max. 0.045 max.备注：明确表示镇静钢时，以最后字符'％”表示，例如，SWRM 10K。
°SAE/AISI化学成分(%)标准号C Mn P S Si10050.06 max. 0.35 max. 0.040 max. 0.050 max. -10060.08 max. 0.25~0.40 0.040 max. 0.050 max. MM 10080.10 max. 0.30~0.50 0.040 max. 0.050 max. MM 10100.08~0.13 0.30~0.60 0.040 max. 0.050 max. MM 10120.10~0.13 0.30~0.60 0.040 max. 0.050 max. MM 10130.11~0.16 0.50~0.80 0.040 max. 0.050 max. MM 10150.13~0.18 0.30~0.60 0.040 max. 0.050 max. MM 10160.13~0.18 0.60~0.80 0.040 max. 0.050 max. MM 10170.15~0.20 0.30~0.60 0.040 max. 0.050 max. MM 10180.15~0.20 0.60~0.90 0.040 max. 0.050 max. MM 10190.15~0.20 0.70~1.00 0.040 max. 0.050 max. MM 10200.18~0.23 0.30~0.60 0.040 max. 0.050 max. MM 10210.18~0.23 0.60~0.90 0.040 max. 0.050 max. MM 10220.18~0.23 0.70~1.00 0.040 max. 0.050 max. MM 10230.20~0.25 0.30~0.60 0.040 max. 0.050 max. MM 10250.22~0.28 0.30~0.60 0.040 max. 0.050 max. MM 10260.22~0.28 0.30~0.60 0.040 max. 0.050 max. MM 2. 硬钢线材°JIS化学成分(%)标准号C Si Mn P SSWRH 270.24~0.31 0.15~0.35 0.30~0.60 0.040 max. 0.040 max.SWRH 320.29~0.36 0.15~0.35 0.30~0.60 0.040 max. 0.040 max.SWRH 370.34~0.41 0.15~0.35 0.30~0.60 0.040 max. 0.040 max.SWRH 42A0.39~0.46 0.15~0.35 0.30~0.60 0.040 max. 0.040 max.SWRH 42B0.39~0.46 0.15~0.35 0.60~0.90 0.040 max. 0.040 max.SWRH 47A0.44~0.51 0.15~0.35 0.30~0.60 0.040 max. 0.040 max.SWRH 47B0.44~0.51 0.15~0.35 0.60~0.90 0.040 max. 0.040 max.SWRH 52A0.49~0.56 0.15~0.35 0.30~0.60 0.040 max. 0.040 max.SWRH 52B0.49~0.56 0.15~0.35 0.60~0.90 0.040 max. 0.040 max.SWRH 57A0.54~0.61 0.15~0.35 0.30~0.60 0.040 max. 0.040 max.SWRH 57B0.54~0.61 0.15~0.35 0.60~0.90 0.040 max. 0.040 max.SWRH 62A0.59~0.66 0.15~0.35 0.30~0.60 0.040 max. 0.040 max.SWRH 62B0.59~0.66 0.15~0.35 0.60~0.90 0.040 max. 0.040 max.SWRH 67A0.64~0.71 0.15~0.35 0.30~0.60 0.040 max. 0.030 max.SWRH 67B0.64~0.71 0.15~0.35 0.60~0.90 0.040 max. 0.030 max.SWRH 72A0.69~0.76 0.15~0.35 0.30~0.60 0.040 max. 0.030 max.SWRH 72B0.69~0.76 0.15~0.35 0.60~0.90 0.040 max. 0.030 max.SWRH 77A0.74~0.81 0.15~0.35 0.30~0.60 0.040 max. 0.030 max.SWRH 77B0.74~0.81 0.15~0.35 0.60~0.90 0.040 max. 0.030 max.SWRH 82A0.79~0.86 0.15~0.35 0.30~0.60 0.040 max. 0.030 max.SWRH 82B0.79~0.86 0.15~0.35 0.60~0.90 0.040 max. 0.030 max. 备注：按照买方和卖方的协议，含碳量按表中的最小值或最大值可以减少0.01%。
SAE认证(美国机动车工程师学会)美国机动车工程师学会（SAE）的认证：规定了市场上销售的汽车配件（SAE认证）的标准.至于包铅和包塑，是生产工艺，只有通过这道工艺才能保证管子的表面光滑。
目前一般工厂都是采用包铅的，因为包塑的工艺并不是很成熟。
附：SAE标准目录编号名称修订日期字数(千字)页数备注SAE J1019高温输油软管、发动机润滑油软管、以及软管总成试验及程序1990-06-122.665SAE J1037挡风玻璃喷洗器软管2001-082.935SAE J1183弹性材料及部件的疲劳试验推荐指南1998-0211.317SAE J1273液压软管总成推荐操作规程2001-038.6SAE J1288液压制动软管总成的包装、贮存和贮存期1999-042.394SAE J1401公路车辆——采用非石油基液压液体的液压软管总成1999-0912.7SAE J1403真空制动软管1989-073.38SAE J1405液压软管总成可选脉冲试验程序1990-06-182.87SAE J1406液压制动软管在机动车辆上的应用2002-043.816SAE J1527船用燃油软管1993-02-055.6SAE J1570液压盘式制动活塞橡胶防尘套1991-09-303.976SAE J1661CFC-12（R-12）汽车空调系统至HFC-134a（R -134a）改型程序1998-115.268SAE J1662致冷剂改型对于空调系统材料的兼容性1998-113.46SAE J1873传输所含水分试验程序——液压制动软管总成2000-102.474SAE J188动力转向回流软管——高膨胀型1998-013.266SAE J189动力转向回流软管——低压1998-013.29SAE J190动力转向压力软管——钢丝编织型1998-052.985SAE J191动力转向压力软管——低膨胀型1998-053.076SAE J20冷却剂系统软管2002-017.6713SAE J2050高温动力转向压力软管2001-043.46SAE J2064R134a制冷剂汽车空调软管1999-067.3911SAE J30燃料及油软管1998-0635.83SAE J343SAE 100R系列液压软管及软管总成试验及试验程序2001-074.79SAE J51致冷剂12汽车空调系统软管1998-085.698SAE J51附表1.052SAE J517液压软管2001-0435.7通用规范合计25185.22172SAE标准简介SAE各汽车协议和标准的简介1905年初,美国汽车工程师学会(SAE)认识到必须标准化。
welding, cutting and more...High-vacuum extraction . KEMPER Dusty (27). Mini-Weldmaster (28). High-vacuum cartridge filter (29)· Accessories ............................... 30 - 31· High-vacuum extractionand filter unit (32)26Ultra light, flexible and powerful.These are only some properties of this small power pack.Two strong turbines provide an excellent extraction efficiencyand high static pressing. The minimum weight makes it veryflexible and universal for many different applications.A Kem Tex® ePTFE membrane filter cartridge provides thefiltration of superfine dust below 0.1 μm. Thereby this unitis suitable for the separation of alveole exchangeable dusts.The advantage of surface filtration is that the filtercartridge can be cleaned.In case of the Dusty, this happens manually in that minutewhen an essential cleaning will be indicated by theinstrument itself. The collected dust can be removed easilyfrom the lower part of the unit.Different nozzles, welding torches with integrated extraction ormini exhaust arms of the extensive accessory programme canbe connected to the two lugs of this extraction and filter unit.The extraction performance can be controlled steplessly andelectronically.For further accessories see pages 30/31. KEMPER DustyPart No.Description63 100KEMPER Dusty1.6 kW · 1 x 230 V / 50 HzVoltage: 1 x 230 V / 50 HzExtraction performance:340 m³/hMotor power: 1.6 kWNoise level:74 dB (A)Filter efficiency:> 99.9 %Weight:21 kgDimensions (w x d x h):300 x 300 x 690 mmTechnical dataPart No.Description10 902 44Spare filter for KEMPER DustySpare filter69mm300m m300mm₤1,197.00₤309.7027Mini-WeldmasterThis easy to transport high vacuum extraction and filterunit is ideal for the extraction of welding fumes at frequently changing work places.Extraction hoses with a diameter of 45 mm guarantee application at locations difficult to access.Various extraction nozzles with a magnetic foot are available.It is also possible to connect one or two welding torches with integrated extraction.The Mini-Weldmaster is equipped with a two stage filter and has a filter efficiency of 99.9 %. It is also possible to retrofit the unit with an activated charcoal filter. Cleaning of the filter inserts is not necessary.Depending on the actual operating time and the substances to be captured the filter has to be changed once or twice a year.A filter monitor indicates a necessary filter change.For more convenient handling a trolley with castor wheels and an automatic start-stop is available.For further accessories see pages 30/31.Part No.Description10 900 34Pre-filter mats, (10 per set)10 900 09Main filter10 900 08Activated charcoal filterSpare filtersVoltage:1 x 230 V / 50 Hz 3 x 400 V / 50 Hz Extraction performance:340 m³/h 270 m³/h Motor power: 1.6 kW 1.1 kW Noise level:71 dB (A)71 dB (A)Filter efficiency:> 99,9 % according to BGIA classification M Weight:24 kg 28 kgDimensions (w x d x h):340 x 450 x 660 mm 340 x 450 x 660 mmTechnical dataPart No.Description 91 730Mini-Weldmaster1.6 kW · 1 x 230 V / 50 Hz 91 730 100Mini-Weldmaster1.1 kW · 3 x 400 V / 50 Hz91 731Mini-Weldmaster with activated charcoal 1.6 kW · 1 x 230 V / 50 Hz91 731 100Mini-Weldmaster with activated charcoal 1.1 kW · 3 x 400 V / 50 HzUnits₤37.30116.40233.60₤1,330.002,659.001,563.002,893.0028With its four air intakes this mobile extraction and filter unit offers a flexible unit for the extraction of polluted air directly at source.It can be used on multiple operations in the metal working industry.The unit can be connected to exhaust nozzles, mini exhaust arms or shields with integrated extraction. The use of torches with integrated extraction makes it even more flexible.The robust extraction unit is supplied with two Kem Tex ® ePTFE membrane filter cartridges, which are monitored by the electrical control and – according to the saturation rate –cleaned automatically during operation.The extraction capacity can be controlled by a stepless adjustable speed control.For further accessories see pages 30/31.High-vacuum cartridge filter unit, mobilePart No.Description82 600High-vacuum cartridge filter unit, mobile 3.3 kW · 3 x 400 V / 50 Hz 94 102 600 02Sensor clamp for the automatic start-stopFan performance:max. 600 m³/h Motor power: 3.3 kW Amperage:7 APressure:20,000 PaVoltage:3 x 400 V / 50 Hz Filter efficiency:> 99,9 %(BGIA classification M)for info on filter cartridges see page 33Compressed air supply: 3.0 - 5.0 bar Weight:178 kg Dimensions (w x d x h):655 x 825 x 1,315 mm Noise level:70 dB (A)Technical dataPart No.Description 10 902 44Spare filter forhigh-vacuum cartridge filter unit, mobileSpare filter₤6,683.00495.60₤309.7029AccessoriesTrolleyPart No.Description91 750 200Trolley for Mini-Weldmaster incl. 4 guide rollers, with brakesExtraction hosePart No.Description93 070 004Extraction hose Ø 45 mm, length: 2.5 m 93 070 005Extraction hose Ø 45 mm, length: 5.0 m 93 070 006Extraction hose Ø 45 mm, length: 10.0 mSlit nozzle 300 mmPart No.Description23 200 08Slit nozzle, 300 mm, with magnetic footSlit nozzle 600 mmPart No.Description23 200 09Slit nozzle, 600 mm, with magnetic footFunnel nozzlePart No.Description23 200 10Funnel nozzle flexible, with magnetic footWelding shieldPart No.Description280 010 030Welding shield with integrated extraction₤49.9098.70191.10₤119.50₤128.80₤126.80₤101.80₤89.8030AccessoriesAdaptor for welding torchesFor connection with a hose, Ø 45 mm.Part No.Description10 600 71Adaptor for welding torches with integrated extraction 42 - 44 mm 10 601 04Adaptor for welding torches with integrated extraction 39 - 42 mm 10 600 84Adaptor for welding torches with integrated extraction 30 - 38 mmMini-Exhaust armPart No.Description91 350Exhaust arm, Ø 50 mm, length: 740 mm, without exhaust nozzle, swivelling to all directions, tubes made of aluminium,joints made of molded plastic incl. standard fixing device.Other exhaust arm diameters on request.Mounting bracketsPart No.Description93 008 001Table mounting bracket incl. two screw clamps 93 008 002Wall mounting bracket incl. screws and rawlplugsNozzlesPart No.Description232 0002Slit nozzle, width 200 mm 232 0004Tube nozzle, Ø 50 mm232 0005Plexiglass nozzle, 245 x 220 mm232 0006Funnel nozzle, round, extraction hole Ø 210 mm₤7.307.307.30₤220.20₤44.5032.50₤54.9019.1068.4064.2031High-vacuum extraction and filter unitPart No.:91 0100 20091 0200 20091 0300 200Filter cartridges:Kem Tex ®ePTFE-membrane filter for surface filtration Filter efficiency:> 99.99 % according to BGIA classification L, M Filter efficiency:For alveole exchangeable dusts see page 33Extraction performance:3,300 m³/h 4,000 m³/h 4,500 m³/h Pressure:18,000 Pa 18,000 Pa 20,000 Pa Motor power:22.0 kW 30.0 kW 37.0 kW Voltage:3 x 400 V / 50 Hz 3 x 400 V / 50 Hz 3 x 400 V / 50 Hz Compressed air supply: 5.0 to 6.0 bar 5.0 to 6.0 bar 5.0 to 6.0 bar Weight:1,050 kg 1,150 kg 1,350 kg Dimensions (w x d x h):2,375 x 1,413 x 2,015 mm 2,826 x 1,413 x 2,015 mm 3,277 x 1,413 x 2,015 mmTechnical dataHigh-vacuum extraction and filter units of the system 9000are very suitable for the connection of several extraction elements and for the construction of central extraction systems for welding workshops, grinding shops or the like.The extracted harmful substances will be separated at the surface of the Kem Tex ® ePTFE membrane filter. The control,based on a Siemens Simatec S7, monitors the collected dust on the surface of the cartridges. On reaching a certain limit it automatically activates the cleaning process during operation of the unit.The robust filter unit, contructed of reinforced steel panels,consists of two parts being connected on site.The following table gives an overview of the standard units.Units with higher outputs are available.For further information on extraction and filtration unitssystem 9000 see pages 70 to 82.32Due to the Kem Tex ® ePTFE membrane filter the KEMPER extraction and filtration systems act as reference for all extraction units.KEMPER extraction and filtration systems are yet efficient where other filtration units are no longer able to filter even the smallest particles. Especially the range of particle sizes smaller than 0.4 μm is very important for the filtration of dusts generated during welding and cutting processes. Because the particles below 0.4 μm are alveole exchangeable.Pulmonary alveoli are the smallest units in the human lung where oxygen is exchanged between the inhaled air and the human blood. Particles reaching the pulmonary alveoli can also diffuse into the bloodstream, form deposits all over the body and, depending on the chemical structure of the particles, can cause cancer.It is absolutely essential for extraction and filtration systems to filter even those finest particles since it is the only possibility to protect your employees and yourself against serious diseases.The BGIA (German government safety organisation) tests on the particle size distribution of welding smoke has shown the following results (E308-16).The Kem Tex ® ePTFE membrane filters can filter particles smaller than 0.4 μm, which represent 98.9 % of the total dust particles, according to BGIA tests.The effective pore size of the Kem Tex ® ePTFE membrane filter is that small, that even particles with 0.1 μm already will be filtered up to 92 %. The equal zero-emission of the Kem Tex ®ePTFE membrane surpasses all current regulations even for superfine particles. Especially with superfine dusts theKem Tex ® ePTFE membrane filters prevent a penetration of the particles.Kem Tex ® ePTFE membrane filters are therefore the ultimate technology concerning all applications. They are yet efficient where conventional filters of the filter class “M” reach their limit. About 90 % less particles reach the air in comparison with conventional filters.Trust in the experience of KEMPER and keep your air clean with Kem Tex ® ePTFE membrane filters!KemTex ® ePTFE membrane filterParticles Ø in μm <0.2<0.4<0.6<0.8<1.0>1.0Quantity 8002519012% of the quantity 75.323.60.900.10.2% of the mass15.938.77.58.229.733Your distributor:P a r t N o . 691 2440-3 · P r i n t e d o n e c o l o g i c a l l y b e n e fi c i a l p a p e r .All prices are exclusive of the current VAT.Priced catalogue items will be delivered carriage paid, within the EU (mainland),incl. packaging. For orders below a net price of £400.00, a standard carriage charge of £15.00ex. VAT, for packaging, insurance and carriage will be raised.All orders are subject to our conditions of sale.Price and technical specifi cations are subject to change without notice. We do not accept any liability for misprints. With the publication of this price list, all former price list loose there validity.The technical specifi cations stated in our catalogue are subject to change withoutnotice. This catalogue is protected by copyright and remains our property.This catalogue can be reclaimed at anytime.Reprints, or partial reprints can only beaccepted with written authorisation by KEMPER .KEMPER (U.K.) Ltd. · Venture Court · 2 Debdale Road · Wellingborough · Northamptonshire NN85AA·Tel.01327872909·Fax01327872181·**************.uk·。
