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ISO 19642-7: Automotive Cables – Dimensions and Requirements

Started by Tacettin İKİZ, December 15, 2024, 07:11:28 PM

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Tacettin İKİZ

ISO 19642-7: Automotive Cables – Dimensions and Requirements



1. Scope and Purpose 

**ISO 19642-7** specifies the **dimensions** and **technical requirements** for copper conductor cables used in automotive applications, with the following characteristics: 

Key Features: 
  • Voltage Rating: Designed for systems operating at up to **30 V AC** or **60 V DC**.
  • Construction Options: Includes both screened and unscreened cables, with single or multi-core designs.
  • Conductor Material: Copper conductors ensure optimal electrical performance.
  • Applications: Suitable for power distribution, control circuits, and signal transmission in road vehicles.

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2. Construction of ISO 19642-7 Cables 

1. Conductor: 
- **Material:** Annealed copper, which can be bare or tinned for enhanced corrosion resistance. 
- **Design:** Stranded conductors to provide flexibility, necessary for the compact and dynamic environment of automotive systems. 

2. Insulation: 
- **Material:** Thermoplastic or cross-linked polyethylene (**XLPE**) insulation for durability, temperature resistance, and low dielectric loss. 

3. Screening (Optional): 
- **Material:** Aluminum or copper braiding or foil for electromagnetic compatibility (EMC) in high-interference environments. 
- Protects sensitive circuits from external EMI (electromagnetic interference). 

4. Sheath (Optional): 
- **Material:** Polyvinyl chloride (**PVC**) or other thermoplastic materials for mechanical protection, environmental resistance, and flexibility. 

5. Shape and Size: 
- Round, single-core, or multi-core configurations to meet specific automotive design requirements. 

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3. Dimensions and Voltage Ratings 

1. Voltage Classifications: 
- **30 V AC:** Low-voltage alternating current systems, typically for lighting and signaling. 
- **60 V DC:** Low-voltage direct current systems, commonly for battery connections, control circuits, and low-power components. 

2. Cross-Sectional Areas: 
- Standard sizes ranging from **0.5 mm² to 16 mm²**, depending on the current-carrying capacity and application. 

3. Diameter Specifications: 
- Defined tolerances for cable diameter ensure consistency and compatibility with connectors and automotive systems. 

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4. Applications of ISO 19642-7 Cables 

These cables are designed for various automotive applications, including: 

  • Power Distribution: Supplying power to low-voltage systems such as lights, wipers, and HVAC components.
  • Control Systems: Wiring for sensors, actuators, and control modules.
  • Communication Systems: Transmitting signals in data buses or audio systems.
  • Battery Connections: Connecting batteries to starter motors or alternators in low-voltage circuits.

Example Use Case: 
An **unscreened, multi-core cable** specified under ISO 19642-7 is used to connect a vehicle's HVAC control unit to actuators, ensuring reliable operation under varying temperature conditions.

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5. Advantages of ISO 19642-7 Cables 

1. Flexibility: 
- Stranded copper conductors and thermoplastic insulation allow easy routing in tight automotive spaces. 

2. Durability: 
- High resistance to mechanical wear, temperature fluctuations, and exposure to automotive fluids. 

3. Electromagnetic Compatibility (EMC): 
- Screened versions reduce EMI, ensuring signal integrity in data and control circuits. 

4. Compliance with Automotive Standards: 
- Designed to meet global automotive safety and performance requirements. 

5. Environmentally Resistant Materials: 
- Protection against UV, moisture, and chemicals ensures a long service life. 

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6. Testing and Compliance Requirements 

To ensure compliance with **ISO 19642-7**, cables undergo rigorous testing: 

1. Electrical Tests: 
- **Conductor Resistance:** Verifies electrical efficiency. 
- **Insulation Resistance:** Confirms minimal current leakage. 

2. Mechanical Tests: 
- **Abrasion Resistance:** Ensures durability under mechanical stress. 
- **Tensile Strength and Elongation:** Verifies robustness of conductor and insulation materials. 

3. Thermal Tests: 
- **Heat Aging Test:** Evaluates insulation performance under prolonged high temperatures. 
- **Cold Bend Test:** Confirms flexibility and integrity at sub-zero temperatures. 

4. Environmental Tests: 
- **Chemical Resistance:** Validates resistance to automotive fluids, such as oils and coolants. 
- **UV Resistance:** Ensures cables maintain performance when exposed to sunlight. 

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7. Comparison with Related Standards 

StandardKey Features
ISO 19642-7Focuses on round, sheathed, screened, or unscreened copper conductor cables for 30 V AC/60 V DC systems.
ISO 6722-1General requirements for cables in road vehicles, including high and low voltage systems.
JASO D 608Heat-resistant, low-tension cables for automotive applications.

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8. Conclusion 

**ISO 19642-7** provides comprehensive specifications for automotive cables used in low-voltage systems, ensuring they meet the demanding requirements of modern vehicles. These cables deliver safety, reliability, and durability, supporting various power, control, and communication applications in automotive environments.

Key Takeaway: 
ISO 19642-7 cables are designed to ensure high performance, durability, and safety, contributing to the efficiency and reliability of modern automotive systems.



"ISO 19642-7 cables: Reliable and durable solutions for modern automotive low-voltage systems."
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