Browse Topic: Electric cables

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Research on the Protection Design of Flexible Cables for Civil Aircraft2026-99-18287/17/2026
Flexible cables are widely used in aircraft and are essential for ensuring the proper functioning of critical systems and flight safety. The design and validation of these cables represent a foundational technology in enabling the transmission of electrical power and signals throughout the entire aircraft. To achieve their intended service life, appropriate protective measures and experimental verification must be implemented. Drawing on the development experience of flexible cables for a specific domestic aircraft model, this paper proposes a combined protection method designed to extend the service life of flexible cables. Experimental analysis demonstrates the practicality and reference value of this approach.
Shi, Liqing, Hu, Huanghua, Ge, Zengwen
Dynamic Characterisation and Modelling of Electrical Cables under Representative Load Conditions2026-01-06766/20/2026
Electric high voltage (HV) cables are commonly used in automotive applications and very prominently in electrified vehicles. These cables are potential flanking transmission paths for structure-borne sound in a broad frequency range and must therefore be included in the NVH design process. Electrical high voltage cables exhibit non-linear mechanical characteristics, when exposed to significant bending the internal geometry of the cable will change and a curvature dependent bending stiffness will result. The electrical cables envisaged in the current publication feature a helically wound stranded aluminium wire core. This conductive core is covered by, in sequence, a silicone rubber insulation, a braided aluminium wire shield with aluminium foil to minimize electromagnetic interference and a silicone rubber outer sheath. An extensive measurement campaign was carried out to dynamically characterize cable specimen of different lengths and cross sections in terms of multi-degree of freedom transfer stiffnesses from 20 to 2000 Hz. In order to investigate possible temperature dependences this dynamic characterisation was carried out for temperatures ranging from -30 until +60 °C. Moreover, additional measurements on bent cable specimen allowed to assess the dependence of the bending stiffness on the cable curvature. It is shown that suitable results can be obtained by modelling the conductive core using an isotropic multi-layer continuum model and by using corrected material characteristics to account for curvature effects. Temperature effects are shown to be negligible within the tested range.
Nijman, Eugene, Buchegger, Blasius, Böhler, Elmar, Zeller, Bernhard, Rejlek, Jan, Faksa, Lukáš, Lukavsky, David
Electric Health-Monitoring Wiring (E-Wiring) for Aircraft2026-26-07856/1/2026
Modern aircraft depend on extensive electrical wiring networks for power distribution, avionics, and control systems; however, these wiring systems are vulnerable to wear, insulation degradation, and arcing over time, leading to safety risks and costly unscheduled maintenance. This paper introduces an advanced Electric Health-Monitoring Wiring (E-Wiring) system that integrates temperature, current, insulation, vibration, and environmental sensors directly into aircraft wiring harnesses to enable continuous monitoring and intelligent fault detection. Data from these embedded sensors are processed through a distributed edge AI network, forming an Electrical Health Monitoring System (EHMS) capable of real-time diagnostics, predictive maintenance, and fault localization. The architecture comprises smart cable segments with sensor nodes, local harness gateways for edge processing, aircraft-level EHMS integration via AFDX/Ethernet, and cockpit or maintenance displays linked to ground-based cloud analytics for fleet-wide insights. We have an existing method to detect by using acoustic sensing method which can detect ongoing insulation chafing or a cut, they are limited in identifying pre-existing damages and by adding multiple acoustics in the existing wire harnesses it’ll add extra load to the aircraft. To overcome this, the system incorporates Time Domain Reflectometry (TDR) technology to detect both existing and potential wiring faults. The TDR circuitry interfaces with onboard devices, injecting test signals into wiring to pinpoint insulation anomalies or conductor breaks without adding significant weight or complexity. The proposed E-Wiring and EHMS solution enhances aircraft safety, reduces maintenance costs, and improves operational availability, offering a scalable approach for both retrofit and new-generation aircraft.
Tammana, Bala Sai Sri Rohit, Murthy, Harsha, Mendu, HarikaSivaniSunandha
SLEEVE, CHAFE-PROTECTION, WRAP-AROUND, SELF-CLOSING (-55 TO +200 °C)AS60491/1 (Current)5/6/2026
AE-8D Wire and Cable Committee
SLEEVE, CHAFE-PROTECTION, EXPANDABLE (-55 TO +200 °C)AS60491/3 (Current)5/6/2026
AE-8D Wire and Cable Committee
SLEEVE, CHAFE-PROTECTION, WRAP-AROUND, SELF-CLOSING (-55° TO +260°C)AS60491/2 (Current)5/6/2026
AE-8D Wire and Cable Committee
Sleeve, Protection, for Cable and Harness ProtectionAS60491A (Current)5/5/2026
Procurement specification is principally for defining protection sleeves on a cable or group of electrical/fiber optic wires (wiring bundle). Single wire protection depends on the minimum diameter of the wire. Sleeve may be used to protect a wire bundle for a platform installation or for repair of installed damaged jacket or jacket/shielded wire bundles. Refer to AS50881 for aerospace wire bundle protection installations.
AE-8D Wire and Cable Committee
SLEEVE, CHAFE-PROTECTION, HIGH ABRASION EXPANDABLE (-55 TO +200 °C)AS60491/4 (Current)4/29/2026
AE-8D Wire and Cable Committee
SLEEVE, CHAFE-PROTECTION, EXPANDABLE (-55 TO +240 °C)AS60491/5 (Current)4/29/2026
AE-8D Wire and Cable Committee
10BASE-T1S (UTP and J-UTP) Unshielded Balanced Single Twisted Pair Ethernet CableJ3117/4_202603 (Current)3/24/2026
This SAE Standard covers a single Un-Jacketed (UTP) and Jacketed (J-UTP) Balanced Unshielded Twisted Pair data cable intended for use in surface vehicle cables for 10 Mb/s Ethernet shared bus applications. The tests in this document are intended to qualify cables for normal operation in an automotive environment while maintaining the necessary electrical properties for reliable data transmission.
Cable Standards Committee
Seven Conductor Cable for ABS Power - Truck and BusJ2394_202603 (Current)3/11/2026
This SAE Standard establishes the minimum construction and performance requirements for seven conductor 1/8-2/10-4/12 cable for use on trucks, trailers, and converter dollies for 12 VDC nominal applications. Where appropriate, the standard refers to two types of cables (Type F and S, described later in the standard), due to the variation in the performance demands of cables used in flexing and stationary applications. While the document’s title refers to ABS Power to differentiate the document from the SAE J1067 standard that it supersedes, the scope applies to both the primary green cable for powering ABS and lighting and the yellow auxiliary cable of the same construction.
Truck and Bus Electrical Systems Committee
Novel Approach on Material Characterization Testing of Various Wiring Harness2026-26-05481/16/2026
The automotive wiring harness (length of 4-5 km) is a very important and complex system in the development of a modern car due to lot of new electric & electronic components and sensors. It is a very sensitive material unlike metals and is considered as a composite which is highly anisotropic in nature, as it consists of several different layers of copper/aluminum strands and insulation. Because of insulation, wiring harness exhibits viscous plastic behavior which is crucial in determining the durability and long-term performance of the cables. Material property has a crucial role in determining the behavior of wiring harness after assembly into the car. Wiring harness may undergo Bending, Torsion and Tension loads, causing the stress and strain in the individual electrical wires. The lack of CAE validation of the wiring harness routing may lead to extra costs for the automotive OEMs during product development. This study explains the novel method of Testing the Cables and Bundles present in cars to get the material properties of it. The procedural description is applicable to single core, multi core and Bundles containing various configurations of cables. Initial assessment tests have been carried out before confirming the methodology for this testing, to ensure the repeatability of test results among various Test samples. The findings from this testing are Bending stiffness, Torsional stiffness and Axial(Tensile) stiffness for calculating the length-independent stiffness of the wiring harness material. The result plots from this Testing contain flow curves to determine the modulus of elasticity, ultimate strength etc., and cyclic curves to determine the Visco-plastic properties of the wiring harness. Material properties from this Testing will be used in the digital development of wiring harness CAE during vehicle development.
Beesetti, Siva, Kalkala Balakrishna, Prasad, James Aricatt, John, Shah, Dipam, Tas, Onur, Krogmann, Stephan
Comparative Analysis of Pothole Depth Estimation Using LIDAR and Stereo Imaging with Polarized Lenses: A DOE Approach2026-26-02691/16/2026
Potholes are a common road hazard that significantly compromise road safety. Water filled potholes can be particularly dangerous. These hidden hazards may cause vehicles to hydroplane [1], leading to a loss of control and potential collisions. At night or in low visibility conditions, such potholes can appear deceptively shallow, increasing the risk of severe suspension damage or tire blowouts. Additionally, deep water intrusion can affect critical components such as the exhaust system, air intake, or electrical wiring, potentially leading to engine stalling or short circuits. This research proposes a novel approach for identifying and determining the depth of potholes, especially those that are filled with water. By integrating YOLO, cutting edge computer vision methods like stereo imaging and Lidar. We hope to create a system that can precisely detect and evaluate potholes' severity, reducing the risks connected to these road hazards. A structured 2k factorial Design of Experiment (DOE) methodology is used to extensively evaluate the performance, accuracy, and limitations of both approaches under a variety of surface and environmental conditions. The stereo imaging approach uses polarization to enhance contrast and reduce glare, which significantly increases depth estimate accuracy in difficult lighting conditions. On the other hand, the LIDAR technique produces 3D point cloud data with excellent resolution, allowing for accurate depth assessment even in low visibility situations. To ensure a reliable comparison between the two systems, the DOE framework carefully specifies the water content, lighting, measurement distance, and important experimental factors. Furthermore, interaction analysis is used to look at how system and environmental factors work together to affect each method's accuracy and dependability.
Ashok, Deeksha, Kumar, Pradeep, Singh, Amandeep
Sleeving, Identification, Heat Shrinkable, General SpecificationAS6976A (Current)12/16/2025
This SAE Aerospace Standard (AS) establishes the requirements for various types of identification sleeving that will shrink to a predetermined size upon the application of heat after it has been marked using AS23053 sleeves as basis material. This AS does not cover specific carrier configuration.
AE-8D Wire and Cable Committee
Guide for Identification of Terminal Lugs in Electrical Wiring Interconnect Systems (EWIS)ARP6807A (Current)10/2/2025
The intent of the SAE Aerospace Recommended Practice (ARP) is to provide a process for users to identify the part number of AS7928 terminal lugs installed in civilian or military applications, although it can also be used to identify terminals that have been stored incorrectly. This ARP is subject to change to keep pace with experience and technical advances of AS7928 terminals. A current set of tables are provided to list and identify current AS7928 terminal lug configurations per the associated specification detail sheet and terminal lug configuration. Specific configuration details, graphic, size, and marking information for each individual terminal lug is provided to assist the product user with accurate selection for replacement or identification.
AE-8C2 Terminating Devices and Tooling Committee
Methods of Shield Termination for Two-Piece, Crimp-Style Ferrule on Shielded CablesARP7503 (Current)10/2/2025
AS21608 shield terminating, crimp-style ferrule applications on shielded cables require various piece parts in multiple combinations to ground the shield of non-environmental cables. This ARP provides the recommended methods to ensure the shield ground wire is terminated correctly and the shield is protected. Refer to AS83519 for shield grounding when eviornmental resistance is required.
AE-8C2 Terminating Devices and Tooling Committee
Low Voltage Primary CableJ1128_202508 (Current)8/22/2025
This SAE Standard covers low voltage primary cable intended for use at a nominal system voltage of 60 VDC (25 VAC) or less in surface vehicle electrical systems. The tests are intended to qualify cables for normal applications with limited exposure to fluids and physical abuse.
Cable Standards Committee
Low Voltage Battery CableJ1127_202508 (Current)8/20/2025
This SAE Standard covers low voltage battery cable intended for use at a nominal system voltage of 60 VDC (25 VAC) or less in surface vehicle electrical systems. The tests are intended to qualify cables for normal applications with limited exposure to fluids and physical abuse.
Cable Standards Committee
CABLE, ELECTRICAL, 600 VOLTS, PORTABLE, MULTICONDUCTOR, OZONE RESISTANTAS5756/4C (Current)8/19/2025
AE-8D Wire and Cable Committee
15 Pole Connector Between Towing Vehicles and Trailers with 12 Volt Nominal SupplyJ2691_202507 (Current)7/21/2025
This SAE Standard establishes the minimum construction and performance requirements for a 15 pole connector between towing vehicles and trailers, for trucks, trailers, and dollies, for 12 VDC nominal applications in conjunction with SAE J2742. The connector accommodates both power and ISO 11992-1 signal circuits along with dual ground wires to accommodate grounding requirements within the constraints of the SAE J2691 terminal capacity.
Truck and Bus Electrical Systems Committee
800P3-2 Cabin Connectors and Cables, Part 3, Specification of CablesARINC800P3-2 (Current)7/7/2025
This specification describes the general cable and wire characteristics recommended for use in cabin systems for commercial aircraft. Supplement 1 adds new definitions of 26 AWG 2-pair (Quad), 4-pair (Oct) data cables, and copper-fiber optic hybrid composite cables. Supplement 2 includes definitions of shielded twisted pair ethernet over single pair for data rates up to 1000Base-T1.
Airlines Electronic Engineering Committee
Seven Conductor Cable - Truck and BusJ1067_202507 (Current)7/1/2025
This SAE Standard establishes the minimum construction and performance requirements for seven conductor 1/8-1/10-5/12 cable for use on trucks, trailers and converter dollies for 12 VDC nominal applications. Where appropriate, the standard refers to two types of cables (Type F and S, described later in the standard), due to the variation in the performance demands of cables used in flexing and stationary applications.
Truck and Bus Electrical Systems Committee
Conceptual Design of a Superconducting Aero Electric Engine System2025-01-01465/2/2025
The goal of the development of an electric aircraft engine is to create an aircraft system that achieves ultimate efficiency using hydrogen fuel instead of fossil fuels. Therefore, it is necessary to focus on reducing weight as much as possible, and this paper describes the approach to such fuel cell-powered aircraft. The authors have adopted a superconducting coreless rotating electric machine with an integrated hydrogen tank and are pursuing a target of 70kg or less for the main components of a 2MW rotating electric machine. High-temperature superconducting cables have zero electrical resistance and can carry a very high current density, but the alternating current (AC) loss generated when used in AC has been an issue in their application to rotating electric machines. In 2023, The SCSC cable was developed to be a low-AC-loss, robust, and high current cable concept, in which copper-plated multifilament coated conductors are wound spirally on a core. In addition to using this superconducting cable, the structure is designed to minimize the weight required to maintain the cryogenic state, and it consists of a single structure that combines a hydrogen tank and a rotating electric motor. This new type of superconducting rotating machine combines flux concentrated type field rotor technology and canned motor technology and provides a seal structure and bearings that make it practical. To put superconducting rotating machines to practical use in electric aircraft engines, it is necessary to transmit high currents from fuel cells, and this system proposes a flexible superconducting cable for power transmission with a hydrogen supply function that combines light weight and flexibility. As a result of performance estimation, we have confirmed that this superconducting rotating machine has the potential to improve performance by more than 10 times compared to our conventional products.
Oyori, Hitoshi, Sakurai, Sho, Kusase, Shin, Yoshida, Yukihiro, Yoshinaga, Seiichiro, Nose, Hiroyuki, Amemiya, Naoyuki
Wire and Cable Marking Process, UV LaserAS5649B (Current)5/1/2025
This standard is applicable to the marking of aerospace vehicle electrical wires and cables using ultraviolet (UV) lasers. This standard specifies the process requirements for the implementation of UV laser marking of aerospace electrical wire and cable and fiber-optic cable to achieve an acceptable quality mark using equipment designed for UV laser marking of identification codes on aerospace wire and cable. Wiring specified as UV laser markable subject to AS4373 and which has been marked in accordance with this standard will conform to the requirements of AS50881.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Single Conductor Cable for Heavy-Duty Applications - Truck and BusJ2549_202504 (Current)4/16/2025
This SAE Standard establishes the minimum construction and performance requirements for single conductor cable for use on trucks, trailers, and converter dollies.
Truck and Bus Electrical Systems Committee
Wire and Cable Splices: Preferred Methods for Use with Automated Wire Processing SystemsARP6673 (Current)4/14/2025
The purpose of this ARP is to provide information on splices, and the definition of the preferred methods of splicing single core wires and multi-conductor cables supplied on reels by vendors, to facilitate their processing on automated wire processing systems to allow continued uninterrupted machine operation without requiring operator intervention.
AE-8D Wire and Cable Committee
Power over Coaxial: a simplified path to advanced vehicle systems25AUTP03_073/1/2025
As automotive technology advances, modern vehicles increasingly rely on complex electronics such as cameras, sensors, radar and lidar. These components are critical for advanced driver-assistance systems (ADAS) and automated driving. With the growing complexity of these systems, automotive manufacturers face challenges in efficiently transmitting both power and data while minimizing weight and system complexity. Power over Coaxial (PoC) technology offers a solution by allowing the transmission of power and data over a single coaxial cable, significantly simplifying vehicle design. With the integration of more electronic systems, especially those required for ADAS and autonomous driving, the demand for power and high-speed data transmission in vehicles has surged. Modern cars now use multiple cameras and sensors, and as vehicle systems continue to evolve, the number of electronic components is expected to increase. This shift places significant demands on the transmission of both data and power across the vehicle's electrical system.
Thurman, Travis
Guidelines for Harness Critical Clamp Locator Marker Installation on Electrical Cable AssembliesARP5614A (Current)10/8/2024
This ARP specifies the recommended methods of marking electrical wiring and harnesses to aid in the positioning/routing of electrical wiring, harnesses and cable assemblies.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
2.5/5/10GBASE-T1 Shielded Balanced Single Pair Ethernet CableJ3117/3_202409 (Current)9/10/2024
This standard covers a single shielded balanced pair (twisted or parallel) jacketed data cable intended for use in surface vehicle cables for 2.5, 5, and 10 Gb/s Ethernet applications. The tests in this standard are intended to qualify cables for normal operation in an automotive environment while maintaining the necessary electrical properties for reliable data transmission.
Cable Standards Committee
Recommended Method for the Testing of Impact Resistant Products on CablesJ3350_202405 (Current)5/9/2024
This SAE Standard describes the methods for testing flexible harness coverings for use on ground vehicle electrical distribution systems, specifically protection from severe mechanical impact. This SAE Standard shall apply to all tapes, extruded tubes, and textile sleeves used for this purpose.
Harness Covering Standards Committee
Aircraft Electrical Wiring Organization - Key to an Autonomous AIF-0080-2024-00055/7/2024
An essential component for the advancement of autonomous flight lies in the development of an intelligent routing system designed to facilitate the maintenance and troubleshooting of electrical wiring. Utilizing software with the capability to present routed paths in a computer-aided design (CAD) format allows for a detailed representation of the rules governing the layout of wiring around structural supports and distribution channels. Despite this, three-dimensional (3D) methodologies have yet to fully incorporate critical data related to the characterization of individual wiring signals, hindering automatic routing. This paper underscores a competitive edge that can be achieved by expanding 3D capabilities to accurately depict the current state of wiring signals in terms of temperature, humidity, electromagnetic frequency, amperage, and other relevant factors. Achieving this involves integrating a non-intrusive smart sensing technology with the intelligent routing system to monitor and diagnose the health and integrity of the wiring system. With this integration, a more robust artificial intelligence (AI) system can leverage the obtained data to make more precise decisions, enhancing overall system performance.
Rhysing, Daryian
Wireless Power Transfer in Aircraft Systems2024-01-19273/5/2024
The aerospace industry is noticing significant shift towards More Electric Aircraft (MEA). The advancement of electrical technology the systems are being transformed towards electric compared to the conventional pneumatic or hydraulic systems. This has led to an increased demand in electrical power from 150 Kilo Watts in the conventional airplane to 1 Mega Watts in More Electric Aircraft. More electric systems, call for increased electrical wiring harness to connect various systems in the aircraft. These harnesses consist of power and data cables. Wireless communication technology is being matured for data communication, leading to reduction of wire harness for data. As of now, the length of wires in large commercial aircraft is over 100miles and it may not be surprising if the electrification of aircraft drive this too much longer. In this paper, a comparative study of various wireless power transfer techniques for DC voltage configuration and the corresponding challenges in an aircraft environment are presented. Challenges in meeting the certification standards as per the RTCA DO-160 for EMI/EMC and power quality are discussed. From various Wireless Power Transfer (WPT) techniques, the technology, architecture suitable for aerospace application is discussed. The models and simulation results are presented. Possibility of deploying WPT alongside WAIC strategy is proposed. The performance of the proposed current control methodology is presented. Potential for future research is laid out based on the study of various technologies.
C S, Adishesha, Thirunarayana, Ashok Kumar, Shreshthi, Mahadevanna, Barik, Mridul Sankar, Banerjee, Kumardeb
INSULATION SLEEVING, ELECTRICAL, HEAT SHRINKABLE POLYTETRAFLUOROETHYLENEAS23053/12B (Current)2/16/2024
AE-8D Wire and Cable Committee
Highest-Resolution Single-Photon Superconducting CameraTBMG-500062/1/2024
The NIST camera is made up of grids of ultrathin electrical wires, cooled to near absolute zero, in which current moves with no resistance until a wire is struck by a photon. In these superconducting-nanowire cameras, the energy imparted by even a single photon can be detected because it shuts down the superconductivity at a particular location (pixel) on the grid. Combining all the locations and intensities of all the photons makes up an image.
INSULATION SLEEVING, ELECTRICAL, HEAT SHRINKABLE, POLYOLEFIN 1/, DUAL-WALL, OUTER WALL CROSSLINKEDAS23053/4A (Current)12/5/2023
AE-8D Wire and Cable Committee
Metal Clad Fibers for Electrical Shielding and Harness OverbraidAIR5464A (Current)12/5/2023
Over the past two and one-half decades several metal clad fibers and fabrics have been developed to provide aerospace vehicle designers with a conductive, lighter weight alternative to coated copper, coated stainless steel and steel wire used for cable and wire shielding and harness overbraids on electrical cables. Several of these candidates have been unable to provide the strength or thermal stability necessary for the aerospace environment. However, several polymer-based products have shown remarkable resistance to the rigorous environment of aerospace vehicles. Concurrent with these fiber developments, there have been changes in the structures of aerospace vehicles involving greater use of nonmetallic outer surfaces. This has resulted in a need for increased shielding of electrical cables which adds substantial weight to the vehicle. Thus, a lighter weight shielding material has become more critical to meet the performance requirements of the vehicle. This report covers the properties of metal clad aramid fibers (MCAF), metal clad polybenzobisoxazole (PBO) fibers (MCPF), and metal clad liquid crystal polymer (LCP) fibers (MCLF), with test results when these products are used as a shield or harness overbraid and a listing of some of the known applications in the aerospace field. The use of these fibers as an electrical conductor in high strength tethers and other aerospace applications are new developments that show the versatility of MCF not only for weight savings, but also for applications where high strength and long flex life are required.
AE-8D Wire and Cable Committee
WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSS-LINKED MODIFIED ETFE, NORMAL WEIGHT, SILVER-COATED, HIGH STRENGTH COPPER ALLOY, 200 °C, 600 VOLT, ROHSAS22759/35B (Current)11/20/2023
AE-8D Wire and Cable Committee
WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSS-LINKED MODIFIED ETFE, NORMAL WEIGHT, NICKEL-COATED, COPPER, 200 °C, 600 VOLT, ROHSAS22759/41B (Current)11/20/2023
AE-8D Wire and Cable Committee
Insulation Sleeving, Electrical, Heat Shrinkable, General Specification forAS23053C (Current)11/15/2023
This specification establishes the requirements for various types and colors of electrical insulating sleeving that will shrink to a predetermined size upon the application of heat. This specification includes provisions for demonstrating compliance with qualification requirements (see Section 4 and 7.3), in process inspection, and statistical process control inspections (see 4.4). The continuous operating temperature ranges for the sleeving classes covered by this specification are from -112 to +482 °F (-80 to +250 °C). The continuous operating temperature range for each sleeving class is given in the applicable detail specification.
AE-8D Wire and Cable Committee
AS23053/12 Heat Shrink Sleeving Specification Change from Dielectric Strength to Breakdown VoltageAIR23054 (Current)10/16/2023
Establish justification for the use of breakdown voltage for product electrical properties instead of calculated dielectric strength.
AE-8D Wire and Cable Committee
WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSSLINKED MODIFIED ETFE, NORMAL WEIGHT, TIN-COATED, COPPER, 150 °C, 600 VOLT, ROHSAS22759/34B (Current)7/24/2023
AE-8D Wire and Cable Committee
WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSSLINKED MODIFIED ETFE, NORMAL WEIGHT, SILVER-COATED, COPPER, 200 °C, 600 VOLT, ROHSAS22759/43B (Current)7/24/2023
AE-8D Wire and Cable Committee
Relative Thermal Life and Temperature Index for Insulated Electric WireAS4851A (Current)7/24/2023
This test method provides performance data on candidate insulation systems as a function of time and temperature. These data give engineering information on the wire insulation candidate relative to the performance of materials already in use with a backlog of experience. These tests expose candidate insulation systems to a wide range of temperatures for short and long periods of time, while measuring the degradation of its physical properties. For aerospace use, end-point proof tests include mandrel bend, water soak, and dielectric integrity.
AE-8D Wire and Cable Committee
PERFORMANCE SPECIFICATION FOR ULTRASONICALLY WELDED WIRE TERMINATIONSUSCAR38-2 (Current)7/11/2023
This specification defines test methods and performance criteria for ultrasonically welded wire-to-terminal bonds as shown in Figure 1. This specification subjects parts to environmental exposures to simulate a lifetime of field exposure for a road vehicle. Exposures referenced in this specification include thermal shock, temperature humidity cycling, and mechanical stress. This specification is intended to evaluate the strength and performance of the interface between wires and the electrical terminal pad. The graphics used are specific to the linear weld type of process equipment. Validation of the terminal is a separate task (refer to a component validation test such as SAE/USCAR-2). If the weld under test (WUT) is different than described in this section or is subjected to conditions beyond what is typical of automotive use, the test sequence may not be applicable. Ensure that parts used in other conditions are validated for the actual conditions encountered. Vehicle and product conditions applicable to use of this specification are: 1 Applicable use: This specification is applicable where the wire and terminal are part of an electrical connection system used in road vehicles at ambient temperatures from -40 to +150 °C. Applied voltage may be either low (0 to 60 VDC) or high (to 1000 VAC or VDC). USCAR-38 applies to all wire lengths and includes a special test for wires shorter than 500 mm where a weld is done after another component has been assembled to assess potential process damage to the terminal at the other end of the wire. Wire harness makers typically will be given the responsibility to track short wire applications per a statement in the applicable engineering statement of work. 2 Applicable designs: The procedures described are applicable to buss, terminal, or device connections, including eyelet and battery terminations comprising either single or multiple wire terminations. Designs with and without crimped insulation wings are applicable. 3 Applicable multiple wire configurations: For multi-wire welds, 12 or fewer wires is preferred since having over 12 wires increases the cost and complexity of the weld. A design review is recommended for welds having over 12 wires to see if splitting the splice into smaller pieces is a better choice. Welds of ≥20 wires are not applicable (because welds of that complexity require equipment capability assessments beyond the scope of USCAR-38). The ratio of the smallest wire size to the total weld cross-sectional area is recommended to be at least 1:10 (i.e., the smallest cable must be at least 10% of the total cross-sectional area of the weld). 4 Applicable wire: This specification was developed using clean, bare, uncoated, stranded automotive wire. Wire with tin coatings, applied lubricants, or contamination is known to affect the mechanical and electrical performance of ultra-sonically welded cable terminations, and are not applicable to be evaluated per this specification. USCAR-38 is not applicable for wire-to-wire splice welding (USCAR-45 is applicable). 5 Applicable wire sizes and types: Copper wire sizes between 0.22 to 150 mm2 per ISO 6722-1 or ISO 19642-3 and aluminum sizes between 0.5 to 150 mm2 per ISO 6722-2 or ISO 19642-4 are applicable. Other wire types may be tested but cannot claim compliance. Examples of “other” wire types are compressed core, compacted core, solid wire core, and center strand materials other than copper, copper alloy, aluminum, or aluminum alloy. Examples of different center strand materials are copper-clad or steel-center-core wires. 6 The validation process described applies only to linear ultrasonic welding, typically with pressure, energy, and amplitude set as inputs and weld time controlled by limiting energy based on “feedback” from process monitoring sensors. Using process feedback assures the energy-per-weld is maintained. If the equipment used to make samples for USCAR-38 testing is different from this description, this specification may need to be modified or may not be applicable.
USCAR
Un-Shielded Balanced Single Twisted Pair Ethernet CableJ3117_202307 (Current)7/10/2023
This document covers un-shielded balanced single twisted pair data cable intended for use in surface vehicle cables for 100 Mbps Ethernet applications. The tests in this document are intended to qualify cables for normal operation in an automotive environment while maintaining the necessary electrical properties for reliable data transmission.
Cable Standards Committee
803-5 Fiber Optic System Design GuidelinesARINC803-5 (Current)7/5/2023
The purpose of ARINC Report 803 is to provide design and implementation guidelines together with a selection guide, providing a fiber optic system design engineer with documentation to assess the design requirements for an aerospace fiber optic installation.
Airlines Electronic Engineering Committee
CABLE, POWER, ELECTRICAL, 600 VOLTS, PORTABLE, SINGLE CONDUCTOR, NON-OZONE RESISTANTAS5756/1C (Current)6/28/2023
AE-8D Wire and Cable Committee
Low Voltage Ultra-Thin Wall Primary CableJ1678_202306 (Current)6/19/2023
This standard covers ultra-thin wall low voltage primary cable intended for use at a nominal system voltage of 60 VDC (60 VAC rms) or less in surface vehicle electrical systems. The tests are intended to qualify cables for normal applications with limited exposure to fluids and physical abuse. This standard covers SAE conductor sizes which usually differ from ISO conductor sizes.
Cable Standards Committee
Connectors, Electrical, Reverse Bayonet, General Specification forAS95234C (Historical)6/6/2023
AS95234 includes reverse bayonet coupling, high current electrical connectors that are watertight and principally used in shipboard, ground vehicles and ground support equipment applications at serve voltages from 200 to 3000 Vrms and temperatures between -55 °C and +125 °C (-67 °F and +257 °F). See 6.1.5 for applications details. For aerospace application connectors, refer to AS50881.
AE-8C1 Connectors Committee
Guide for the Design of Threaded Screw or Stud Type Electrical Equipment TerminationsAIR38D (Current)6/5/2023
To establish design recommendations that will provide a basis for safe and reliable connections to threaded screw-type or stud-type electrical equipment terminations. These recommendations are directed primarily, but not solely, to the aerospace and ground support equipment industries. Since individual design criteria may alter the details as outlined, it is therefore important that this SAE Aerospace Information Report (AIR) not be considered mandatory but be used only as a design guidance.
AE-8C2 Terminating Devices and Tooling Committee
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