Browse Topic: Cable and wire harness

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Wetting prediction of power train components under the influence moving components using smooth particle hydrodynamics2026-26-03841/16/2026
Passenger cars are subjected to extensive conditions ranging from driving through wet roads, water puddles, icy roads, and rain. This can affect the performance of different parts over time, one such aspect is the vehicle corrosion, whose impact is felt on a wide spectrum from aesthetics to safety due to loss of material. The general condition for corrosion mainly requires electrolyte to be present on the metal surface, which is transported through self-soiling and foreign soiling. Vehicle soiling is an important aspect for vehicle design. Amongst the many aspects of vehicle soiling, one important aspect is the prediction of water accumulation that enables prediction of corrosion sensitive regions in the vehicle. Power train components like Engine, transmission and corresponding wiring harness are at highest risk of water-wetting, As the vehicle drives through the water pool the components are not just wet by the direct inflow of water but also by water being splashed by moving
Shukrey, Sarthak, Pattankar, Rohan, Yenugu, Srinivasa
Life Cycle Assessment of Automotive Cables and GHG Emission Reduction Scenario in Indian Context2026-26-02401/16/2026
Globally, the emissions share of transport is 15%, out of which more than 2/3rd emissions are contributed by road transport as per 2014 report of Intergovernmental Panel on Climate Change (IPCC). The need of mitigation measures in transport sector has been realised however the study of life cycle emission needs to be done with the tailpipe emissions so that some holistic solution can be worked upon. Strikingly, in the life cycle studies of a passenger car, it was found that the share of raw materials related to copper is around 50% of the total amount of raw material used and the share of copper in the curb weight of vehicle is just 1%. Also, for an Internal Combustion Engine vehicle (ICE), mostly the copper is used in the wiring harness. In this paper, the life cycle assessment of wiring harness is done to understand the environmental impacts throughout the life cycle stages. The comparative study of aluminium alloy and copper has also been done to know the change in environmental
Kumar, Naman, Bawase, Moqtik, Thipse, Sukrut
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 a 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 properties play an important 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 over a period. This paper describes the novel method of Testing the Cables and Bundles used in
Beesetti, Siva, Kalkala Balakrishna, Prasad, James Aricatt, John, SHAH, Dipam, Tas, Onur, Krogmann, Stephan
ABSTRACT Unified Test Automation System for Safer and Sustainable Automotive Electrical Systems2026-26-05031/16/2026
This research introduces a new, modular, and digitally integrated method and system for testing and evaluation of wire harness systems and other electrical and automotive subassemblies. The testing system utilises a wireless, cloud-integrated platform. Each node is having test points, which allows the system to test complex wire harness / circuits in real-time. The solution reduces the requirement for complex manual setup changes and produces rapid results to make the test process more accurate, traceable and consistent. The patented testing system works using a modular wireless architecture where many nodes are digitally connected to evaluate complex electrical devices. When a component, such as a wiring network or PCB, is connected to the board, the system automatically runs a predefined test sequence. These tests check for circuit account, signal integrity, insulation resistance and other important parameters. The system provides real-time results through cloud integration, while a
Sancheti, Rahul Madanlal
Electro Magnetic Radiation Analysis for the Vehicle Cable and Shielding Techniques and Performance Assessment2026-26-05631/16/2026
This paper addresses the challenges and methodologies for evaluating radiated emissions from automotive electronic systems, which is critical for achieving electromagnetic interference and compatibility (EMI/EMC) standards. The rapid integration of advanced electronic components in modern vehicles has transformed automotive systems, their potential to generate electromagnetic interference (EMI) becomes a significant concern, particularly due to its impact on vital communication and safety systems. The study mainly investigates radiated EMI, which is the unintentional emission of electromagnetic energy emitted by HV cables in the wiring harness layout, potentially disrupting the operation of nearby systems. This study utilized CST Studio Suite to analyse the electromagnetic behaviour of vertically and horizontally polarized antenna configuration in electric vehicles. The simulated results are benchmarked against international EMI/EMC standards such as CISPR-12 and CISPR-25, which
MANUELRAJ, MASILAMANI, Narayanan, Siva Suriya, prasad PhD, Suryanarayana
Design Optimization of Hydrogen Engine Vanity Cover for PSHA Compliance using CFD leakage analysis2026-26-02631/16/2026
Abstract: The integration of hydrogen (H2) as a fuel source in internal combustion engines (ICE) necessitates stringent design measures to mitigate leakage risks and ensure operational safety. This study focuses on the design optimization of vanity cover for hydrogen engines which only serves the purpose for hiding fuel system, wire harness & engine aesthetic else there is no engineering function like sealing, load factor associated with it. This paper addresses the challenges and risks of using Vanity cover on Internal combustion engines, if fuel joints inside the cover start leaking and forms hydrogen cloud which if not ventilated or diluted properly will have safety risk considering low ignition of hydrogen. Computational fluid dynamics (CFD) analysis is carried out to assess and control hydrogen leakage through fuel rail connections, injector interfaces and associated high pressure fuel system components. Detailed modelling of hydrogen flow behavior, diffusion characteristics of
Veerbhadra, Swati Ashvinkumar, Sahu, Abhay Kumar, Singh, Rahul
Integrated Powertrain Domain Controller Using Wide Band Gap Devices For EV Applications2026-26-00551/16/2026
The rapid evolution of electric vehicles (EVs) has amplified the demand for highly integrated, efficient, and intelligent powertrain architectures. In the current automotive landscape, EV powertrain systems are often composed of discrete ECUs such as the OBC, MCU, DC-DC Converter, PDU, and VCU, each operating in isolation. This fragmented approach adds wiring harness complexity, control latency, system inefficiency, and inflates costs making it harder for OEMs to scale operations, lower expenses, and accelerate time-to-market. This paper addresses the core issue of fragmented control architectures in EV powertrains by proposing an integrated domain controller-based solution for EV powertrain. The technical gap lies in the absence of a centralized intelligence capable of seamlessly managing and synchronizing the five key powertrain aggregates: OBC, MCU, DC-DC, PDU, and VCU under a unified software and hardware platform. This fragmentation leads to redundancy in computation, increased
Kumar, Mayank, Deosarkar, Pankaj, Inamdar, Sumer, Tayade, Nikhil
Innovative Inverted Cross Car Beam Design for Optimized Packaging of Advanced Driver Assistance Technologies in Global Vehicles.2026-26-00511/16/2026
• Objective This paper proposes an innovative inverted cross car beam design optimized for packaging advanced driver assistance system (ADAS) technologies, including Augmented Reality Head-Up Display (AR-HUD) systems, within premium vehicle instrument panels. The study emphasizes the use of lightweight steel structures bracketry's and advanced joinery techniques to address challenges such as NVH (Noise, Vibration, and Harshness), durability, and BSR (Buzz, Squeak, and Rattle) while maintaining structural integrity and luxury aesthetics. By focusing on alignment precision, vibration damping, and efficient space utilization, the design supports the seamless integration of ADAS components, enabling the development of future-ready global EV vehicles with high-performance premium interiors. • Novelty This paper introduces a groundbreaking U-shaped steel tube cross car beam design that addresses the growing demands of ADAS integration, such as AR-HUD, steering column, HVAC systems, and ECUs
MAHAJAN, AJAY SENU, Regatte, Ganesh, Nagarjuna, Kamisetti, SAHOO, SANDEEP, Udugu, Kumaraswamy, JC, sudheera
Arc Damage Assessment of Arc Plume and Physical DamageAIR6982 (Current)11/26/2025
Describes the relative measurement of assessing the damage zone of arc plasma to determine appropriate separation/segregation requirements between a wire harness and nearby components
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Guidelines for Specifying LVDTs and RVDTsARP5554 (Current)11/26/2025
As per Committee/Henry E. Harschburger recommendations
A-6B1 Hydraulic Servo Actuation Committee
Impact of Engine Failure on the Wiring Harness Design of Electric VTOL AircraftF-0080-2024-10525/7/2024
This paper deals with the influence of engine failure during hover on the wiring harness mass of electrical Vertical Take-Off and Landing (eVTOL) aircraft. It starts by presenting possible strategies which can be used to distribute the additional thrust needed during an engine failure among the remaining engines. The most efficient strategy is selected and the impact of different single engine failures on the overall thrust share, while using this strategy, is discussed. The paper proceeds by applying the selected thrust compensation strategy to the mission simulation of three common reference models, which are representative of current eVTOL aircraft configurations. This simulation is used to determine the worst flight phase for the One Engine Inoperative (OEI) condition to occur. The main purpose of the simulation is to optimize the wire sizes of the wiring harness of each configuration while satisfying different design objectives. The results of these optimizations are used to
Oberschwendtner, Sebastian, Hornung, Mirko
Improving the Sound Transmission Loss of Wire Harness Pass Throughs2025-01-01185/5/2023
Abstract Improving the Sound Transmission Loss of Wire Harness Pass Throughs For years the NVH community has known that openings in the dash sheet metal, such as holes to pass wire harnesses through, create an acoustical weak point that limits the potential noise reduction of the dash insulation system. These pass throughs can also be a source of water leaks into the vehicle’s interior. With the combustible engine and now electric inverter power plants, the need to seal this area is vital. By molding a lightweight barrier that draws through the fiber/absorber interior decoupler and dash sheet metal which mates to a secondary seal molded into an outer engine dash decoupler, the two opposing molded barriers meet in the engine compartment and compress together forming a seal around the wire harness. This male/female molded seal replaces the conventional snap in grommet and eliminates noise/water leaks. The system Sound Transmission Loss (STL) is equivalent to similarly insulated sheet
Check, James, Moritz, Charles
115/200 Volt, 400 Hz Aircraft External Electrical Power Connector Contact Maintenance ProceduresAIR4365B (Current)9/30/2021
This SAE Aerospace Information Report (AIR) describes procedures for use in the field to determine if 115/200 Volt, 400 Hz aircraft external electrical power connectors are excessively worn, which may result in the inability of the external power plug to be retained, intermittent electrical performance and arcing.
AGE-3 Aircraft Ground Support Equipment Committee
Evaluation of Cable Harness of an Electric Vehicle Powertrain through Simulation2021-26-03509/22/2021
The Electric Vehicles (EV) or Hybrid Electric Vehicle (HEV) has a bunch of electrical/electronic components and its operation give rise to complicated EMI/EMC issues. The Power Electronics Module (PEM), comprising of DC-DC convertor and Battery Management Unit (BMU), is driving the inverter and motor to propel the vehicle. “Battery Pack Module” powers these units through cables. The fast switching of these circuit elements present in the system leads to noise propagation through the cables. These noise signals give rise to various Electromagnetic (EM) related issues in the cable harness of vehicle. It is essential that these cables should not interfere with other electronic components and also does not get effected by external EM disturbances. The critical EM aspects such as Cable Coupling, Immunity of cable in EM environment (Radiated Immunity) as per AIS-004, Emission from the power cables (Radiated Emission) as per AIS-004, Shielding Effectiveness for cable harness of the EV
H, Rajesh, Mahajan, Rahul, Dandge, Sunil
Guide for Installation of Electrical Wire and Cable on Aircraft Landing GearAIR4004A (Current)8/9/2021
Recent field experience has indicated significant problems with some types of wire and cables as routed on aircraft landing gear. This SAE Aerospace Information Report (AIR) is intended to identify environmental concerns the designer should consider, materials that appear to be most suitable for use in these areas, routing, clamping, and other protection techniques that are appropriate in these applications. In recent years aircraft certification regulatory agencies introduced new regulations regarding Electrical Wiring Interconnection Systems (EWIS) to further enhance safety of the associated systems and aircraft overall.
A-5B Gears, Struts and Couplings Committee
CABLE ASSEMBLY EXTERNAL ELECTRIC POWER, AIRCRAFT 115/200 VOLT, 400 HERTZAS90328A (Current)8/5/2021
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Unshielded High Voltage Primary CableJ1654_202107 (Current)7/15/2021
This SAE Standard covers unshielded cable, 22 gauge and larger, intended for use at a nominal system voltage up to 600 V or 1000 V (ACrms or DC). It is intended for use in surface vehicle electrical systems.
Cable Standards Committee
CABLE, LOW INDUCTANCE, 270 VOLT DCAS5756/7B (Current)7/15/2021
AE-8D Wire and Cable Committee
Unshielded High Voltage Primary CableJ1654_202107-TEST-REC (Historical)7/15/2021
This SAE Standard covers unshielded cable, 22 gauge and larger, intended for use at a nominal system voltage up to 600 V or 1000 V (ACrms or DC). It is intended for use in surface vehicle electrical systems.
Cable Standards Committee
CABLE, POWER, ELECTRICAL, 600 VOLTS, PORTABLE, MULTICONDUCTORAS5756/3B (Current)6/22/2021
AE-8D Wire and Cable Committee
Fundamentals in Wire Selection and Sizing for Aerospace ApplicationsAIR6540B (Historical)4/30/2021
The scope of this report is to capture fundamental principles of selecting a wire size for an aerospace application using the method prescribed in the AS50881 standard and additional calculations, not found in AS50881, to ensure the wire selection will adequately perform in the specific physical and environment conditions. This report covers wire selection and sizing as part of the electrical wire interconnection systems (EWIS) used in aerospace vehicles. Aerospace vehicles include manned and unmanned airplanes, helicopters, lighter-than-air vehicles, missiles, and external pods. This document does not apply to wiring inside of airborne electronic equipment but shall apply to wiring externally attached to such equipment. Wire selection must consider physical and environmental factors to size wires such that they have sufficient mechanical strength, do not exceed allowable voltage drop levels, are protected by materials or circuit protection devices, and meet circuit current carrying
AE-7C Systems
Fundamentals in Wire Selection and Sizing for Aerospace ApplicationsAIR6540B-TEST-REC (Historical)4/30/2021
The scope of this report is to capture fundamental principles of selecting a wire size for an aerospace application using the method prescribed in the AS50881 standard and additional calculations, not found in AS50881, to ensure the wire selection will adequately perform in the specific physical and environment conditions. This report covers wire selection and sizing as part of the electrical wire interconnection systems (EWIS) used in aerospace vehicles. Aerospace vehicles include manned and unmanned airplanes, helicopters, lighter-than-air vehicles, missiles, and external pods. This document does not apply to wiring inside of airborne electronic equipment but shall apply to wiring externally attached to such equipment. Wire selection must consider physical and environmental factors to size wires such that they have sufficient mechanical strength, do not exceed allowable voltage drop levels, are protected by materials or circuit protection devices, and meet circuit current carrying
AE-7C Systems
Research in OFDM-Based High-Speed In-Vehicle Network Connectivity for Cameras and Displays2021-01-01514/6/2021
Growing trends of connected and autonomous vehicles have pushed for increased resolutions of cameras to 8Mpix and displays to 4K/8K, leading to requirements for high-speed interfaces that support 10Gbps and beyond. Unlike data center or enterprise networks which normally operates under controlled indoor environments, in-vehicle networks are required to operate in harsh temperature and interference environments. Due to cost restrictions, the use of single pair wire is prevalent for in-vehicle networks. In general, as data transmission speed increase, signal spectrum spreads across greater frequency range. Since insertion loss of a channel increases in proportion to signal frequency, it becomes more difficult to secure SNR (signal-to-noise ratio) margins as bit rate increases. This makes it increasingly difficult for a device (e.g. ECUs, sensors, and displays) with high-speed communication interface to meet EMC (electromagnetic compatibility) criteria imposed by automotive OEMs. If this
Kondo, Taiji, Ueda, Kayo, Serizawa, Naoshi, Koike, Tomoyuki, Kondo, Hisashi
Legibility of Print on Aerospace Wires and CablesARP5607B (Current)1/12/2021
The purpose of this SAE Aerospace Recommended Practice (ARP) is to provide recommendations for marking wire and cable insulations to meet legibility requirements. This information is generic and applies to any type of wire marking system, such as an ultraviolet (UV) laser marking system or an inkjet or other ink based wire marking system. This ARP is limited to the legibility of human-readable characters and does not address bar code or other machine-readable symbols. In this ARP, the term wire refers to jacketed cables and fiber optic cables in addition to individual wires. This ARP defines the factors that affect the legibility of markings on wiring. Two generic types of variables affect legibility: stimulus variables and environmental variables. Stimulus variables are those factors involving the mark itself. This ARP establishes a set of guidelines for key stimulus variables that contribute to legibility and which should be taken into consideration in the course of specifying and
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Surgical Robotics: The Art of Saving Costs with CablesTBMG-383121/1/2021
Ever hear of the respected bicycle manufacturer known as Cannondale? You probably have. Perhaps you even own one of their bikes. I actually do. Since 1971, Cannondale has produced among the most well-recognized and trusted, high-performance bicycle brands in the United States. But they don’t actually make everything their bikes comprise.
AS6021 Aerospace Fiber Optic Cable Assembly Drawing SpecificationAS6021A (Current)12/29/2020
This SAE Aerospace Standard (AS) defines the items that shall be considered when creating a fiber optic cable assembly specification and source control drawing intended for installation on aerospace platforms.
AS-3 Fiber Optics and Applied Photonics Committee
AS6021 Aerospace Fiber Optic Cable Assembly Drawing SpecificationAS6021A-TEST-REC (Historical)12/29/2020
This SAE Aerospace Standard (AS) defines the items that shall be considered when creating a fiber optic cable assembly specification and source control drawing intended for installation on aerospace platforms.
AS-3 Fiber Optics and Applied Photonics Committee
The Influence of the Wiring Harness on the System Performance of eVTOL Aircraft on the Example of Common Reference ModelsF-0076-2020-1640410/5/2020
This paper deals with the influence of the wiring harness on the system performance of electric vertical take-off and landing (eVTOL) aircraft. The architecture and connections of the wiring harness are formalized using graph theory. The adjacency and incidence matrices provided by algebraic graph theory are used to define the harness connections and links. The current flows within the harness are calculated by applying Kirchhoff’s and Ohm's law to the network equations. Three common reference models are used to simulate and optimize different harness architectures. The harness architectures differ in the kind of connection and number of harness links. The optimization is done using two objectives. One objective is to maximize the range of the aircraft. The other objective, to minimize the harness mass, is used to show the performance difference of such a wiring harness. The influence of the system voltage and the take-off mass are examined as well. The results of the optimizations
Oberschwendtner, Sebastian, Hornung, Mirko
Rapid Prototyping of Cable and Connectors for Unique ApplicationsTBMG-3783310/1/2020
The need for new connector and cable, or modified versions of standard interconnection systems, is growing exponentially. Highly portable electronics and the extension of their use in unique, rugged applications (often in challenging environments), are demanding new designs as well as performance. This is a period of rapid technology development, as designers create new products and instruments with higher-speed circuits that run faster, last longer, and go places we could not imagine.
Electrical Wiring Fuel CompatibilityAIR6820A (Current)9/18/2020
This SAE Aerospace Information Report (AIR) is limited to the subject of compatibility of wiring as part of aircraft Electrical Wiring and Interconnect Systems (EWIS) installed in and around aircraft fuel tanks.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Electrical Wiring Fuel CompatibilityAIR6820A-TEST-REC (Historical)9/18/2020
This SAE Aerospace Information Report (AIR) is limited to the subject of compatibility of wiring as part of aircraft Electrical Wiring and Interconnect Systems (EWIS) installed in and around aircraft fuel tanks.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
How Unlimited-Length Flexible Printed Circuits Are Transforming Electrical Interfaces in Medical DevicesTBMG-375839/1/2020
Undergoing surgery is a costly procedure, often involving a hospital stay and the ongoing monitoring of the patient after discharge. During and after an operation, the patient is put through considerable stress, both mentally and physiologically, which affects the body’s respiratory, cardiovascular, excretory, and immune systems in particular. Whenever possible, limiting the size and number of incisions made during surgery by using minimally invasive surgery (MIS) techniques is extremely beneficial to the patient’s recovery time.
Temporary COVID-Specific Treatment and Testing Facilities Require Distinct Interconnect SolutionsTBMG-375909/1/2020
Since the onset of the COVID-19 pandemic, the diagnostic testing, medical equipment, and healthcare professional communities have shifted much of their focus to temporary facilities requiring radio-frequency (RF) and microwave-dependent communications and diagnostic systems. The overwhelming demand for community-based testing (over 30,000,000+ tests administered to date) was further complicated by the fact that most testing needed to be accomplished in temporary field sites.
Developing Products Amid COVID-19: Innovating Production Systems for Surgical Mechanical Cable MakingTBMG-372337/1/2020
Did you know that to be able to say, “not this again,” in response to the current global health emergency, you would have to be no younger than 102 years old? It’s true. The last time the world saw such a crippling public health crisis, the year was 1918, when the flu pandemic sickened one-third of the world’s population. But, in the throes of a calamity unseen in over a century, which has now even shut down the world’s economy, one would think manufacturing would simply stop as well. And certainly, with unemployment figures estimated to be as high as 20 percent in the United States, the highest ever since the Great Depression, it isn’t difficult to imagine a slowdown in the making of virtually anything built by America’s proud stable of manufacturers.1
CONNECTOR, PLUG, AIRCRAFT EXTERNAL POWER, 115/200 VOLT, 400 HERTZAS7974/1B (Current)5/20/2020
AE-8C1 Connectors Committee
CABLE, SAFETY, FERRULE, ELONGATED AND KITS NICKEL ALLOY, UNS N06600AS3619B (Current)4/6/2020
E-25 General Standards for Aerospace and Propulsion Systems
Aerospace & Defense Technology: April 202020AERP044/1/2020
Coiled Spring Pins What Do They Do? How Do You Install Them? Ruggedizing Coaxial and Fiber Optic Cable Assemblies from Mechanical Strain Bringing Turbine Power to Small Aircraft Bringing Turbine Power to Small Aircraft Limiting Creep in Aerospace Materials Advances in Millimeter-Wave Isolator Design Launch Manufacturers into Stratospheric Operating Frequencies NASA Prepares for the Moon and Mars with Expanded Deep Space Network A Focal Plane Array and Electronics Model for CMOS and CCD Sensors in the AFIT Sensor and Scene Emulation Tool Developing an improved model capable of generating realistic synthetic data that represents a wide range of systems can lead to new algorithms and data exploitation techniques. Deformation Sensing in Soft Bio-Surrogate Materials Accurate measurement of deformations occurring within or on soft materials has recently generated interest for its benefits to the fields of soft robotics and wearable biomedical sensors. Real Time Physiological Status
Ruggedizing Coaxial and Fiber Optic Cable Assemblies from Mechanical StrainTBMG-366124/1/2020
From fiber optics to coaxial cables, common failure points in harsh environments call for various augmentations to enhance an interconnect’s operational lifetime. These modifications can range from the addition of armoring for crush/impact resistance to optimizing cable jacketing material for resistance to chemical/oil ingress. Mechanical strain is often a cause for premature failures of interconnects. Understanding the reasoning and methods behind ruggedizing commonly leveraged interconnects such as fiber optic and coaxial cables can be enlightening.
Ruggedizing Coaxial and Fiber Optic Cable Assemblies from Mechanical Strain20AERP04_024/1/2020
From fiber optics to coaxial cables, common failure points in harsh environments call for various augmentations to enhance an interconnect's operational lifetime. These modifications can range from the addition of armoring for crush/impact resistance to optimizing cable jacketing material for resistance to chemical/oil ingress. Mechanical strain is often a cause for premature failures of interconnects. Understanding the reasoning and methods behind ruggedizing commonly leveraged interconnects such as fiber optic and coaxial cables can be enlightening.
Fluoride Offgassing in Fluoropolymer InsulationsARP6229 (Current)3/24/2020
This SAE Aerospace Recommended Practice (ARP) shall be limited to information about corrosion caused by fluoride offgassing of fluoropolymer-based wire insulation. It reviews published reports of corrosion caused by this phenomenon, describes scenarios where this may be a concern, mitigation options, and references a test method which can be used to evaluate wire insulations where needed.
AE-8D Wire and Cable Committee
CONNECTOR ACCESSORIES, ELECTRICAL, TERMINATION, SHIELD SPLIT SUPPORT RING, COMPOSITE, NONENVIRONMENTAL, STRAIGHT, CATEGORY 7AS85049/93C (Current)3/19/2020
AE-8C1 Connectors Committee
Test Methods for Insulated Electric WireAS4373F (Current)3/12/2020
This standard describes test methods for insulated, single conductor, electric wire intended for aerospace applications. Particular requirements for the wire being tested need to be specified in a procurement document or other detail specification. Suggested minimum requirements are included in the notes at the end of some of the test methods. SAE Performance Standard AS4372 uses some of the tests in this document for evaluating comparative performance of aerospace wires.
AE-8D Wire and Cable Committee
Fundamentals in Wire Selection and Sizing for Aerospace ApplicationsAIR6540A (Historical)3/6/2020
The scope of this report is to capture fundamental principles of selecting a wire size for an aerospace application using the method prescribed in the AS50881 standard and additional calculations, not found in AS50881, to ensure the wire selection will adequately perform in the specific physical and environment conditions. This report covers wire selection and sizing as part of the electrical wire interconnection systems (EWIS) used in aerospace vehicles. Aerospace vehicles include manned and unmanned airplanes, helicopters, lighter-than-air vehicles, missiles, and external pods. This document does not apply to wiring inside of airborne electronic equipment but shall apply to wiring externally attached to such equipment. Wire selection must consider physical and environmental factors to size wires such that they have sufficient mechanical strength, do not exceed allowable voltage drop levels, are protected by materials or circuit protection devices, and meet circuit current carrying
AE-7C Systems
The Benefits of Tungsten CableTBMG-362423/1/2020
There is no one-size-fits-all material when producing mechanical cable. The material chosen to produce wire rope can vary from one application to the next, because commonly, no two applications place the same demands on the stranded cable. Consider tungsten, for instance. Also known as Wolfram (W, atomic number 74), tungsten possesses the highest melting temperature of all metals. For this reason, this rare earth metal is commonly found in light bulb filaments, x-ray tubes, and arc-welding electrodes. Because of such unique mechanical properties, tungsten has become an integral component in the manufacturing of many of today’s cutting-edge medical devices, including surgical robots.
Celebrating Women in Engineering & Science: Mary Hardgrove, Assembly SupervisorTBMG-361863/1/2020
Immunity to Radiated Electromagnetic Fields - Bulk Current Injection (BCI) MethodJ1113/4_202002 (Current)2/24/2020
This SAE Standard defines a method for evaluating the immunity of automotive electrical/electronic devices to radiated electromagnetic fields coupled to the vehicle wiring harness. The method, called bulk current injection (BCI), uses a current probe to inject RF onto the wiring harness in the frequency range of 1 to 400 MHz. BCI is one of a number of test methods that can be used to simulate the electromagnetic field. The test method refers to ISO 11452-4 (please refer to ISO 11452-4 for test procedures). In addition to ISO 11452-4, this test method also includes a differential bulk current injection (DBCI) test. DBCI is described in Section 4 of this document.
Electromagnetic Compatibility (EMC) Standards
Design and Handling Guide Radio Frequency Absorptive Type Wire and Cables (Filter Line, AS85485)AIR4465A (Current)1/31/2020
This document presents design and application information which will allow optimized utilization of filter line wire and cable purchased to AS85485. Filter line wire is defined and design information is presented. The electrical and mechanical performance characteristics of the wire, along with recommended harnessing methods and techniques, are also presented.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Performance Specification for Cable-to-Terminal Electrical CrimpsUSCAR21-4 (Current)1/22/2020
This specification defines test methods and requirements for validation of solderless crimped connections. The purpose of this test is to simulate in the lab the stress seen in a typical life (15 years and 150000 miles) for a crimp connection and assure the crimp is mechanically strong and electrically stable. This specification was developed for use with stranded automotive copper wire. Only where specifically mentioned are other constructions or other core materials (aluminum, clad, steel core, etc.) applicable. This specification does not apply to wire types not mentioned, such as coaxial cable crimps, unless a USCAR-21 test is specifically referenced in the test specification for that wire type. This specification is based on accepted levels of environmental exposure for automotive applications. In any intended vehicle application, if the products covered by this specification are or may be subjected to conditions beyond those described in this document, they must pass special
USCAR
Wired for Autonomy20AVEP01_051/1/2020
Wiring harnesses are already heavy, complex and costly, so what happens when AV equipment is added? Two experts weigh in. Engineers and product planners are already grappling with the complexity of autonomous vehicles (AVs), with the prospect of complexity increasing. Every second, AVs manage advanced-sensor fusion via high-bandwidth networks, while onboard computers run AI algorithms to process gigabits of data. Connecting it all is the wiring harness, which has become increasingly heavy, more expensive and more difficult to package within the vehicle. Premium-segment cars and full-size trucks can contain 40 different harnesses comprised of 700 connectors and more than 3,000 wires. Stretched in a continuous line, these wires would span 2.5 mi (4 km) and weigh approximately 132 lb. (60 kg). In addition, there can be more than 70 specialty cables that include coax, high-speed data and USB runs.
Scott, Dan, Hoff, Ulrike
Marking of Electrical Insulating MaterialsAS5942 (Current)12/27/2019
This specification establishes the performance requirements for the identification of wire and cable by indirect markings that have been applied to electrical insulating materials including heat shrink sleeving, wrap around labels and “tie-on” tags as well as any other types of materials used for indirect marking. This specification covers the processes used to mark these materials, including impact ink marking, thermal transfer, hot stamp, and lasers, etc. This specification does not cover the direct marking on insulated electrical wires and cables.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
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