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Types of Automotive Harness Cables and Wire size Calculations

Wire are used in residential and commercial use to transfer power and signals. Normally, wire is a single, usually cylindrical, flexible strand or rod of metal. Wires come in many forms and are made from many materials.  Best quality raw material enable high performance and long term usage.

Wire

Wire or cables are used in various application. These application can vary like Automotive Cables, Airport Cable, Cables for Oil Industry, Data Cables, Highway Cables, Lan Cables, Military Cables, Mining Cables, Under see cables and British standards Cable etc. Automotive cables vary according to standard use in the industry. There are various standard like German standard, American Standard, Japanese Standard etc. List of Various Automotive Cables: DIN Standards

Sr No Type of Cable

(Germany Std)

Sr No Type of Cable

(American Std)

Sr No Type of Cable

Japanese Standard

1. FLY 1. TWP 1. AV
2. FLYY 2. GPT 2. AV-V
3. FLYW 3. TXL 3. AVS
4. FLRYW 4. GXL 4. AVSS
5. FLYK 5. SXL 5. AVSSH
6. FLRYK 6. HDT 6. AEX/AVX
7. FLRY-A 7. SGT 7. AEXF
8. FLRY-B 8. STX 8. AEXSF
9. FLR2X-A 9. SGX 9. AEXHF
10. FLR2X-B 10. WTA 10. AESSXF
11. FL2G 11. WXC 11. AEXHSF
12. FL2X 12. AVXSF
13. FLRYW-A 13. AVUHSF
14. FLRYWd 14. AVUHSF-BS
15. FLRYW-B 15. CIVUS
16. FLR4Y 16. ATW-FEP
17. FL4G 17. AHFX
18. FLR5Y-A 18. AHFX-BS
19. FLR5Y-B 19. HAEXF
20. FLR6Y-A 20. HFSSF-T3
21. FLR6Y-B 21. AVSSX/AESSX
22. FLU6Y 22. CAVS
23. FLR7Y-A 23. CAVUS
24. FLR7Y-B 24. EB/HDEB
25. FLR9Y-A 25. AEX-BS
26. FLR9Y-B 26. AEXHF-BS
27. FLR12Y-A 27. AESSXF/ALS
28. FLR12Y-B 28. AVSS-BS
29. FLR13Y-A 29. APEX-BS
30. FLR13Y-B 30. AVSSXFT
31. FLR14Y

 

Out of all this AV, AVS, AVSS, FLRY A, FLRY B are the most opted cable for Automotive Industry. Following Table give clear idea about the full form and choice of cable according to application.

Sr No Symbol Long Form Characteristics Heat Resistant
1 AV A: Automobiles

V: Vinyl Compound

ACW: Automotive Composite Wall Wire

S: Slim

SS: super slim

F: Flexible

BS: British Standard

IS: Indian Standard

C: Circular

,

Vinyl Insulated Low tension electric cables for automobiles 800 C
2 AVS Low tension Cables with reduced outside diameter for Automobiles 800 C
3 AVSS Low tension cables with reduced outside diameter for Automobiles 800 C
4 AVX Cross linked Vinyl Heat resistant low tension cables for Automobiles 1000 C
5 AEX Cross linked polyethylene heat resistant low tension cables for automobiles 1200 C
6 ACW Hot oil resistant thin wall 150 excellent resistance at high temp to engine fluids 1500 C
7 FLRY-B Automotive low voltage cable (FL) with reduced insulation thickness (R) made of PVC (Y) and irregularly stranded conductor (B) 1000 C

Wire Stranding and Insulation Type

Wires have various characteristics which are necessary to understand for proper selection. Dimension, electrical characteristics, mechanical characteristics, low temperature characteristics, Resistance to abrasion, heat aging, resistance to chemical and resistance to flame propagation etc. The wire stranding and insulation type can vary widely within one wire size. For an example for a wire size of 0.5 sq.mm no of strands and strand outer diameter changes.

Sr No Cable Type Cable Size (Sq.mm) No of Strands Strand OD Reference Standard
1 FLRY- B 0.50 16 0.21 DIN 72561 Part 6
2 ACW 0.50 19 0.22 ACW 0219
3 BS 0.50 16 0.21 BS 6362
4 AV 0.50 7 0.32 JIS C-3406-1993
5 AVF 0.50 20 0.18 JIS C-3406-1993
6 AVS 0.50 7 0.32 JASO D 611-1994
7 AVSF 0.50 20 0.18 JASO D 611-1994
8 AVSS 0.50 7 0.32 JASO D 611-1994
9 AVSSF 0.50 19 0.19 JASO D 611-1994
10 AVX 0.50 7 0.26 Conductor: JIS C3102
11 IS 0.50 20 0.18 IS – 2465  1984

Wire Size Calculation

Solid Wire

First, let’s understand the concept of solid wire and stranded wire. When a wire has only single conductor then that is called as solid wire. Calculating cross section of such wire is very simple. calculate radius of a conductor and then use (pi * r^2) this formula. 

In stranded wire, the cable has no of conductor of small diameter in one cable. It improves the current caring  capacity of the wire. All automotive cables used are stranded wire in which diameter of each strand changes according to types of cable.

 

Stranded Wire

As mentioned earlier the stranded wire has more than one conductor. Hence to calculate the area of such wire use following steps.

  1. Strip the cable and calculate the no of strands.
  2. Using vernier caliper measure the diameter of a strand.
  3. Find radius of that strand, divide measure length in step two by factor of 2.
  4. Calculate area (A1) of single strand by suing simple mathematical relation (3.14 x radius x radius)
  5.  At last multiply area of a strand with no of strands in the cable.

For example:

  • A copper wire has a 16 strands
  • Diameter of each strand is 0.21 mm
  • So radius will be 0.105 mm
  • Area of single strand will be (3.14 x 0.105 x 0.105) = 0.0346
  • Multiply area of single strand with no of strands in cable (0.0346 * 16) = 0.55

Hence we can say that cable is of 0.5 Sq.mm. We can use this technique fir any automotive cable.

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