【线缆学苑】汽车线束耐久特性与触点压降测试办法的科研
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/YVtazF5mHwexUmCO1YPR1csvptPEcQ0zyQYvoeqECJSupKOsOqO3P38sdNKooib2BrsPBnib5aAMETDnFMkL2muA/640?wx_fmt=png&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"></p><span style="color: black;">随着汽车电气化与智能化水平的<span style="color: black;">逐步</span><span style="color: black;">加强</span>，线束的数量日益庞大。虽然总线技术在现代汽车中广泛应用，使得导线及接插件的数量进一步减少，庞大的线束系统得到精简，<span style="color: black;">加强</span>了线束的轻量化水平，<span style="color: black;">然则</span>线束<span style="color: black;">做为</span>汽车电路的基本网络主体，在汽车电气系统中的地位仍然<span style="color: black;">没法</span>替代。</span>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">汽车线束分布在汽车的<span style="color: black;">各样</span>角落，<span style="color: black;">根据</span><span style="color: black;">重点</span>结构可分成驾驶室线束、底盘线束和发动机线束。其中驾驶室中的门线束<span style="color: black;">长期</span>在反复伸缩下工作；底盘线束<span style="color: black;">长期</span>在高低温和泥浸渍环境下工作；发动机线束大部分时间在高温和高油的环境下工作，并且在发动机<span style="color: black;">起步</span>瞬间必须承担瞬态电流的冲击。汽车线束<span style="color: black;">倘若</span><span style="color: black;">不可</span>适应在这些极端环境下工作，必然<span style="color: black;">引起</span>起火、短路、腐蚀老化等故障，<span style="color: black;">从而</span>直接影响汽车行驶安全，<span style="color: black;">引起</span>事故的<span style="color: black;">出现</span>。为了<span style="color: black;">保准</span>汽车的安全性，对汽车线束的测<span style="color: black;">实验</span>证就<span style="color: black;">显出</span>尤为重要。</span></p><img src="https://mmbiz.qpic.cn/mmbiz_jpg/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMCHUVd8buu4A0xImqtzFSGY5sMiamQPFa92huwpP5KXrKibhM5FGBUYhQ/640?wx_fmt=jpeg&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;"><span style="color: black;">汽车线束标准<span style="color: black;">重点</span>有QCn 29005-1990《汽车用低压电线束质量分等》、QCn 29009-1991《汽车用电线接头技术<span style="color: black;">要求</span>》、QC/T 29106-2014《汽车电线束技术<span style="color: black;">要求</span>》。在线束测试方面，国内<span style="color: black;">重点</span>遵循QC/T 29106-2014 标准，<span style="color: black;">然则</span>这套标准在电性能测试方面存在<span style="color: black;">许多</span>不足：其中<span style="color: black;">针对</span>电性能测试中的触点压降测试，标准中<span style="color: black;">说到</span>的<span style="color: black;">办法</span>在<span style="color: black;">实质</span>测试中并不适用，<span style="color: black;">由于</span>该<span style="color: black;">办法</span>需要的测试设备较多，且需要在热平衡后进行<span style="color: black;">测绘</span>；而<span style="color: black;">针对</span>耐久特性测试，标准中<span style="color: black;">更加是</span><span style="color: black;">无</span>提及。针对标准中电性能测试在这2个测试项目中存在的不足，本文中基于 QC/T 29106-2014标准，提出了新的耐久特性测试和触点压降测试<span style="color: black;">办法</span>，并针对这2种测试<span style="color: black;">办法</span>进行<span style="color: black;">实验</span>验证。</span>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;"><strong style="color: blue;">耐久特性测试</strong></span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">耐久特性测试的目的<span style="color: black;">重点</span>是<span style="color: black;">保证</span>负载类线束在满负荷工作<span style="color: black;">状况</span>下工作一段时间后，导线的温度<span style="color: black;">不可</span>超过故障温度并且线路中的熔断器、接插件、继电器等电器设备<span style="color: black;">不可</span><span style="color: black;">显现</span>烧毁的现象。在QC/T 29106-2014标准中并<span style="color: black;">无</span><span style="color: black;">说到</span>耐久特性测试。</span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;"><span style="color: black;">经过</span>查阅<span style="color: black;">关联</span>文献，传统的耐久特性测试<span style="color: black;">办法</span>为：对测试电路输入一<span style="color: black;">按时</span>间的过载电流后<span style="color: black;">运用</span>温度传感器<span style="color: black;">测绘</span>导线的温度，<span style="color: black;">经过</span>观察导线的温度及外观来判断测试<span style="color: black;">是不是</span>合格。传统的耐久特性测试中<span style="color: black;">运用</span>的是温度传感器来<span style="color: black;">测绘</span>导线温度，这种<span style="color: black;">办法</span>只能反映导线某个<span style="color: black;">测绘</span>点的温度，并<span style="color: black;">不可</span>反映<span style="color: black;">全部</span>导线的温度。<span style="color: black;">因此呢</span>本文中提出了<span style="color: black;">运用</span>红外热<span style="color: black;">影像</span>仪<span style="color: black;">测绘</span>导线温度的<span style="color: black;">办法</span>，该<span style="color: black;">办法</span>能直观快速地从整体观测被测线束的温度。图1为改进的线束耐久特性测试原理图。过载电流的计算公式为:</span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMbHfHRuwl1LJUe27zbYiblfZjLiaBklC4YFfqpGf2vzcQbjan7tFibK9icA/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;"></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">（1）式中：Io 为过载电流；K 为过载电流系数；IA 为熔断器额定电流。过载电流系数K与熔断器的种类<span style="color: black;">相关</span>：Jcase和Mega熔断器K取135%；Midi和BF熔断器K取145%。</span></p><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMgJ6lrHtt9TSxnkKtY6gNBsk514P1VoJJ80aZdhSAGHdwzKHliarx1Qw/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMs7fSTuRFagsXDBcUF3TcZ8fRlqMh4BqrLD7ibCbkobMjjwGbicowiaOWA/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMVk3ichzzBQRibbmKNxwBhOeF8jndthEfQw3ZPrfM8vxNm28HUoTPiaAQQ/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;">
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">图2为某车型电器盒线束进行耐久特性测试的热<span style="color: black;">影像</span>图，图3为线束温度趋势图。该线束回路熔断器为20 A的Jcase熔断器，过载电流:</span></p><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMO04378A3toLEn27YUa6IwlydiaO6g0ZJjKf8hnbHf3lwILX92AoFy1A/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;">
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;"><span style="color: black;">经过</span>测试<span style="color: black;">发掘</span>，电器盒线束在通30 min的过载电流后导线最高温度不超过98℃，<span style="color: black;">少于</span>导线的故障温度105℃。测试结果<span style="color: black;">表示</span>电器盒线束耐久特性测试合格，该<span style="color: black;">办法</span>能有效测试线束耐久特性。</span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">导线温度T与导线发热量Q<span style="color: black;">相关</span>，导线发热量Q<span style="color: black;">按照</span>式（2）计算：</span></p><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMzTPYB5bKfQpCBHibLSdHibMu6SdkatkjFib7Wq3GVoibcMMds8ye2TNZcQ/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;">
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">（2）式中：I为导线电流计算值；R为导线电阻计算值；t为导线通电时间；ρ 为铜的电阻率；l 为导线长度；s 为导线截面积。</span></p><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMA0cXuiap1Hy0uG1uS4xS8WUfEp9BfmOKGCyqicKXvbI4IAxcDkX4O6tQ/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFM8YOBIibj05HbGjd22HsDfabfJnPxNjkzHDjohekzPYGMr6EYbPmr8qw/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;">
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;"><span style="color: black;">这次</span><span style="color: black;">实验</span>中101、102、108导线的参数见表1。根据表1中的数据计算得出101、102、108导线 I2R值 分 别 为 22.7、293.6、317.3，即 导 线 发 热 量Q108＞Q102＞Q101 ， 从 而 得 出 导 线 温 度T108＞T102＞T101 ，与热<span style="color: black;">影像</span>仪<span style="color: black;">测绘</span>出的导线温度趋势（图3）符合。</span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;"><strong style="color: blue;">线束端子触点压降测试</strong></span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;"><span style="color: black;">1.直接测试法</span></strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">QC/T 29106-2014 标准中规定了线束端子触点压降的测试<span style="color: black;">办法</span>：<span style="color: black;">首要</span>按示意图（图 4）进行电路连接，查表2确定<span style="color: black;">实验</span>电流，<span style="color: black;">而后</span>对电路通恒定电流。当温度<span style="color: black;">测绘</span>点连续 5 次的温度读数差<span style="color: black;">少于</span>±2 ℃，即达到热平衡状态，此时分别<span style="color: black;">测绘</span>点A和点 B、点 A 和点 C、点 C 和点 D 之间的电压，导体压接区电压降按式（3）计算：</span></p><img src="https://mmbiz.qpic.cn/mmbiz_jpg/YVtazF5mHweMvvw9ialbjO6piaL05icuPwUuqNiatB1iaibv6hPaIkcxSXbpoYLctt0icKUibBhJZKPiaKy27IUR50IFLKA/640?wx_fmt=jpeg&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMwsQZoSiaNml0vicljQbw3pODD3wYFic8wUjS0aZEiaXEhwAnzUfibVZrvbA/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMibicICmPXXRnQwJlgDyGFKoLGpc4ibAatZBxLncZRyY13xf2PWibpyfm8Q/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;">
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">（3）式中：UAB 为导线压接区电压降；UAC 为<span style="color: black;">测绘</span>点A和点C之间的电压降；UCD 为<span style="color: black;">测绘</span>点C和点D之间的电压降。<span style="color: black;">按照</span>QC/T29106-2014<span style="color: black;">需求</span>，计算出的电压降UAB 应不大于表2中给定的电压降。</span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><strong style="color: blue;"><span style="color: black;">2.间接测试法</span></strong></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">线束端子触点压降产生的本质是端子与导线压接时产生的接触电阻，接触电阻<span style="color: black;">包含</span>收缩电阻、导体电阻、膜层电阻三部分。<span style="color: black;">因此呢</span>本文中提出了一种间接<span style="color: black;">测绘</span>线束端子触点压降的<span style="color: black;">办法</span>——电阻<span style="color: black;">测绘</span>法。该测试<span style="color: black;">办法</span>操作简单，只需一台高精度毫欧表<span style="color: black;">就可</span>完成。本文中线束电阻<span style="color: black;">测绘</span><span style="color: black;">选择</span>的是精确度为1 μΩ 的TH2516B型低电阻测试仪。图5为间接<span style="color: black;">测绘</span>法示意图，图中AB为导线与端子的压接区，试验中只需<span style="color: black;">测绘</span>AC与CD之间的电阻<span style="color: black;">就可</span><span style="color: black;">经过</span>公式（4）计算出压接区接触电阻。</span></p><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMaicvQ0834N3JSn5Kg76qYYH7XdCj6Vunic3iaoYSj0Tb1LMNkZ5ZKZYbQ/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;">
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">（4）式中：RAB 为导线压接区接触电阻；RAC 为<span style="color: black;">测绘</span>点A和点C之间的电阻；RCD 为<span style="color: black;">测绘</span>点C和点D之间的电阻。</span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">由QC/T29106-2014给定的<span style="color: black;">区别</span>截面积导线对应的电压降和<span style="color: black;">实验</span>电流即表2中的值，<span style="color: black;">能够</span>计算出<span style="color: black;">区别</span>导线对应压接点的接触电阻，如表3所示。<span style="color: black;">按照</span>标准中规定电压降 UAB 应不大于表 2 中给定电压降的<span style="color: black;">需求</span>，<span style="color: black;">这次</span>间接<span style="color: black;">测绘</span>法<span style="color: black;">实验</span>中<span style="color: black;">测绘</span>计算的压接点接触电阻应不大于表3中的规定。</span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">表4是某车型部分导线<span style="color: black;">测绘</span>结果，<span style="color: black;">能够</span>看出所有导线压接点接触电阻 RAB 均<span style="color: black;">少于</span>表3中值，即导线与端子触点压降符合标准QC/T29106-2014的<span style="color: black;">需求</span>，测试结果<span style="color: black;">显示</span>线束触点压降符合<span style="color: black;">需求</span>，该<span style="color: black;">办法</span>能有效地进行触点压降测试。</span></p><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMdibr9R5beaDSvaYSic7m0fVTgaj8o0icVVcsRvzzl0VEOHkdsFibHCLHQg/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMwQwMekpX2cJJCQ1wy0eHNVkIfs1odaChG1atoqYewYAB34pOPOdb1A/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/4JpV7k8WdOZu6zj5UYTaTZTC7PeTOibFMXh4tPl1Dt17ZHeRGguXp0qM3v4IGiaicdf7UYPnSAkTib7lqFuYtbd3XQ/640?wx_fmt=png&wxfrom=5&wx_lazy=1&wx_co=1&tp=webp" style="width: 50%; margin-bottom: 20px;">
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;"><strong style="color: blue;">结论</strong></span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">以 QC/T 29106-2014 为测试依据的标准，针对标准中电性能测试<span style="color: black;">办法</span>的不足提出了新的测试<span style="color: black;">办法</span>，得出以下结论：</span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">1.传统的耐久特性测试<span style="color: black;">运用</span>温度传感器记录线束温度，该<span style="color: black;">办法</span>只能<span style="color: black;">测绘</span>导线某个点的温度；本文中提出的<span style="color: black;">运用</span>热<span style="color: black;">影像</span>仪<span style="color: black;">测绘</span>导线温度，<span style="color: black;">能够</span>动态直观的观察<span style="color: black;">包含</span>接插件、导线、电器设备在内的<span style="color: black;">全部</span>线束系统的温度，并且<span style="color: black;">能够</span>快速找到最高温度点从而分析线束的耐久特性；</span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">2.传统的触点压降测试采用的是直接<span style="color: black;">测绘</span>法，该<span style="color: black;">办法</span>需要的测试设备比较多，且需要在恒定电流通电达到热平衡后进行；本文中提出的采用<span style="color: black;">测绘</span>接触电阻来间接<span style="color: black;">测绘</span>触点压降的<span style="color: black;">办法</span>，只需毫欧表<span style="color: black;">就可</span>，不需要搭建测试电路，比传统<span style="color: black;">办法</span>更加简洁、更加<span style="color: black;">有效</span>。</span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><img src="https://mmbiz.qpic.cn/mmbiz_png/YVtazF5mHwfJU2HP0FaherqjBjPkOqLydWrzVrUiaXGLmaGEgXib5fbOcCQVOfr2peLuf4ibpWBoAdIMpqVIntgOA/640?wx_fmt=png&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"><img src="https://mmbiz.qpic.cn/sz_mmbiz_jpg/YVtazF5mHwcibjkTSJa7DB3lEBlDIIWkRr0ull6ib1kAUQ8POBk3xTQGnYIicndZDiaLhvbqOvm4jcbk8cwY0tpRzQ/640?wx_fmt=jpeg&from=appmsg&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;"></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;"><span style="color: black;">来 源 | 线束世界</span></span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">编 辑 | 李 雪、孙荷兰</span></p>
<p style="font-size: 16px; color: black; line-height: 40px; text-align: left; margin-bottom: 15px;"><span style="color: black;">审 核 | 于 锴</span></p><span style="color: black;">投稿热线 | 400-107-5009</span><span style="color: black;">投稿邮箱 | news@chinacable.com</span>”<img src="https://mmbiz.qpic.cn/mmbiz_png/NM7H2WMl4Yk5EMbWibJAzbEtyoqd1o22Qf4mcUXYuIBMMjz8MO2UORYNRmpkhYpSLP3iaGW9j2z2VVHJicciaibhsAg/640?wx_fmt=png&tp=webp&wxfrom=5&wx_lazy=1&wx_co=1" style="width: 50%; margin-bottom: 20px;">
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说得好啊！我在外链论坛打滚这么多年，所谓阅人无数，就算没有见过猪走路，也总明白猪肉是啥味道的。 你的见解真是独到，让我受益良多。 你的话语如春风拂面，让我心生暖意。 你的话语如春风拂面，温暖了我的心房，真的很感谢。 “沙发”（SF，第一个回帖的人） 楼主果然英明！不得不赞美你一下！ 你的话语如春风拂面，让我心生暖意。
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