SAE AIR 4004A-2015 Guide for Installation of Electrical Wire and Cable on Aircraft Landing Gear.pdf

1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there

2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2015 SAE International All rights reserved. No part of this p

3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497

4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AIR4004A AEROSPACE INFORMATION REPORT AIR4004 REV. A Issued 1989-11 Reaffirmed 20

5、10-12 Revised 2015-07Superseding AIR4004 Guide for Installation of Electrical Wire and Cable on Aircraft Landing Gear RATIONALE This SAE Aerospace Information Report (AIR) provides information and criteria updates to reflect the latest standards used in wire, connector, and conduit selection and req

6、uirements for brackets, clamps, and other auxiliary components typically used to dress the landing gear. The report also includes a comprehensive list of the related documents to easily search for more information outside the scope of this document. TABLE OF CONTENTS 1. SCOPE 3 1.1 Purpose . 3 2. RE

7、FERENCES 3 2.1 Applicable Documents 3 2.1.1 SAE Publications . 3 2.1.2 ASTM Publications 5 2.1.3 RTCA Publications 5 2.1.4 NEMA Publications . 5 2.1.5 AIA Publications 5 2.1.6 U.S. Government Publications 5 2.1.7 FAA Publications . 6 2.1.8 EASA Publications 8 2.2 Definitions . 8 3. LANDING GEAR ENVI

8、RONMENT . 8 4. COMPONENTS RECOMMENDED FOR USE ON LANDING GEAR 9 4.1 General . 9 4.2 Wire and Cable . 10 4.3 Protective Tubing (Conduit) 11 4.4 Clamps 15 4.5 SWAMP Connectors . 16 5. ROUTING LOCATION 17 SAE INTERNATIONAL AIR4004A Page 2 of 18 6. ENVIRONMENTAL/EMI CONCERNS 18 7. SUMMARY 18 8. NOTES 18

9、 Figure 1 Typical protective covering . 12 Figure 2 Typical clamp adaptor . 13 Figure 3 Typical adaptors and transitions . 13 Figure 4 Example of change to improve service life by elimination of trapped moisture 14 Table 1 Wire insulation and tubing material acronym list 8 SAE INTERNATIONAL AIR4004A

10、 Page 3 of 18 1. SCOPE 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 b

11、e 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 s

12、afety of the associated systems and aircraft overall. 1.1 Purpose This document is to be used as a general reference for the aerospace community. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this document to the extent specified herein. The latest issue of SAE pub

13、lications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, sup

14、ersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. AMS1431 Compound

15、, Solid Runway and Taxiway Deicing/Anti-Icing AMS1435 Fluid, Generic, Deicing/Anti-Icing Runways and Taxiways AMS-T-81914 Tubing, Plastic, Flexible, Convoluted, Conduit, General Specification for ARP914 Glossary of Electrical Connection Terms AIR1221 Electromagnetic Compatibility (EMC) System Design

16、 Checklist AIR1329 Electrical Connectors and Wiring, Compatibility of AIR1394 Cabling Guidelines for Electromagnetic Compatibility ARP1481 Corrosion Control and Electrical Conductivity in Enclosure Design ARP1870 Aerospace Systems Electrical Bonding and Grounding for Electromagnetic Compatibility an

17、d Safety ARP1931 Glossary of Terms with Specific Reference to Electrical Wire and Cable ARP1972 Recommended Measurement Practices and Procedures for EMC Testing ARP4043 Flight Line Grounding and Bonding of Aircraft ARP4242 Electromagnetic Compatibility Control Requirements Systems AS4372 Performance

18、 Requirements for Wire, Electric, Insulated Copper or Copper Alloy SAE INTERNATIONAL AIR4004A Page 4 of 18 AS4373 Test Methods for Insulated Electric Wire ARP4404 Aircraft Electrical Installations AIR4567 Composite Electrical Connectors ARP4754 Guidelines for Development of Civil Aircraft and System

19、s ARP4761 Guidelines and Methods for Conducting the Safety Assessment Process on Civil Airborne Systems and Equipment AIR4789 Aerospace Information Report on Evaluating Corrosion Testing of Electrical Connectors and Accessories for the Purpose of Qualification AS4851 Relative Thermal Life and Temper

20、ature Index for Insulated Electric Wire ARP5062 Recommended Test Fluids for Electrical Components Used on Aircraft Exterior or for Ground Support Near Aircraft ARP5412 Aircraft Lightning Environment and Related Test Waveforms ARP5413 Certification of Aircraft Electrical/Electronic Systems for the In

21、direct Effects of Lightning ARP5414 Aircraft Lightning Zone ARP5415 Users Manual for Certification of Aircraft Electrical/Electronic Systems for the Indirect Effects of Lightning ARP5416 Aircraft Lightning Test Methods AS5419 Cable, Thermocouple Extension, Shielded and Unshielded ARP5577 Aircraft Li

22、ghtning Direct Effects Certification ARP5583 Guide to Certification of Aircraft in a High-Intensity Radiated Field (HIRF) Environment AIR5919 Alternatives to Cadmium Plating AS6451 Shields, Protective, Aircraft and Missiles AS8700 Installation and Test of Electronic Equipment in Aircraft General Spe

23、cification for AS21608 Ferrule, Shield Terminating, Crimp Style AS21919 Clamp, Loop Type, Cushioned Support AS22759 Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy AS23190 Wiring, Positioning, and Support Accessories AS25064 Conduit, Flexible, Radio Frequency Shielding AS25065 Ferr

24、ule, Flexible Conduit, Radio Frequency Shielding AS25067 Conduit Assembly, Flexible, Radio Frequency Shielding SAE INTERNATIONAL AIR4004A Page 5 of 18 AS29600 Connectors, Electrical, Circular, Miniature, Composite, High Density, Quick Coupling, Environment Resistant, Removable Crimp Contacts Associa

25、ted Hardware, General Specification For AS39029 Contacts, Electrial Connector, General Specification for ARD50055 Aircraft Electrical Systems AS50151 Connectors, Electrical, Circular Threaded, AN Type, General Specification For AS50881 Wiring Aerospace Vehicle AS81044 Wire, Electrical, Crosslinked P

26、olyalkene, Crosslinked Alkane-Imide Polymer, or Polyarlyene Insulated, Copper or Copper Alloy AS85049 Connector Accessories, Electrical General Specification For 2.1.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 61

27、0-832-9585, www.astm.org. ASTM F2639-07 Standard Practice for Design, Alteration, and Certification of Airplane Electrical Wiring Systems ASTM F2696-08 Standard Practice for Inspection of Airplane Electrical Wiring Systems ASTM F2799-09 Standard Practice for Maintenance of Airplane Electrical Wiring

28、 Systems 2.1.3 RTCA Publications Available from RTCA, Inc., 1150 18th Street, NW, Suite 910, Washington, DC 20036, Tel: 202-833-9339, www.rtca.org. DO-160 Environmental Conditions and Test Procedures for Airborne Equipment 2.1.4 NEMA Publications Available from National Electrical Manufacturers Asso

29、ciation, 1300 North 17th Street, Suite 900, Arlington, VA 22209, Tel: 703-841-3200, www.nema.org. WC27500 Standard for Aerospace and Industrial Electrical Cable 2.1.5 AIA Publications Available from Aerospace Industries Association, 1000 Wilson Boulevard, Suite 1700, Arlington, VA 22209-3928, Tel: 7

30、03-358-1000, www.aia-aerospace.org. NAS1713 Clamp, Loop, Cushioned, Center Mounting 2.1.6 U.S. Government Publications Copies of these documents are available online at http:/quicksearch.dla.mil. MIL-DTL-16878 Wire, Electrical, Insulated, General Specification for MIL-DTL-25038 Wire, Electrical, Hig

31、h Temperature, Fire Resistant, and Flight Critical MIL-DTL-26482 Connectors, Electrical (Circular, Miniature, Quick Disconnect, Environment Resisting), Receptacles and Plugs, General Specification for SAE INTERNATIONAL AIR4004A Page 6 of 18 MIL-DTL-26500 Connectors, General Purpose, Electrical, Mini

32、ature, Circular, Environment Resisting, General Specification for MIL-DTL-38999 Connectors, Electrical, Circular, Miniature, High Density, Quick Disconnect (Bayonet, Threaded, and Breech Coupling), Environment Resistant, Removable Crimp and Hermetic Solder Contacts, General Specification For MIL-DTL

33、-83413 Connectors and Assemblies, Electrical, Aircraft Grounding, General Specification for MIL-DTL-83413/8D Connectors and Assemblies, Electrical, Aircraft Grounding: Type IV Jumper Cable Assembly, Lead, Electrical MIL-DTL-83454 Terminal, Stud, Blind Plate, For Electrical Bonding and Grounding (Non

34、insulated) MIL-DTL-83723 Connectors, Electrical, (Circular, Environment Resisting), Receptacles and Plugs, General Specification for MIL-HDBK-274 Electrical Grounding for Aircraft Safety MIL-HDBK-454 General Guidelines for Electronic Equipment MIL-STD-202 Test Method Standard, Electronic and Electri

35、cal Component Parts MIL-STD-461 Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment MIL-STD-464 Electromagnetic Environmental Effects, Requirements for Systems MIL-STD-470 Department of Defense Handbook, Designing and Developing Maintainable Produ

36、cts and Systems MIL-STD-704 Aircraft Electrical Power Characteristics MIL-STD-810 Department of Defense Test Method Standard, Environmental Engineering Considerations and Laboratory Tests MIL-STD-882 Standard Practice for System Safety MIL-STD-889 Dissimilar Metals MIL-STD-1560 Insert Arrangements f

37、or MIL-DTL-38999, MIL-DTL-27599 and MIL-C-29600 Series A Electrical Circular Connectors MIL-STD-7080 Selection and Installation of Aircraft Electric Equipment MIL-STD-464 Electromagnetic Environmental Effects Requirements for Systems 2.1.7 FAA Publications Available from Federal Aviation Administrat

38、ion, 800 Independence Avenue, SW, Washington, DC 20591, Tel: 866-835-5322, www.faa.gov. Sections applicable to landing gear wiring: Part 23 Airworthiness Standards: Normal, Utility, Acrobatic, and Commuter Category Airplanes Part 25 Airworthiness Standards: Transport Category Airplanes SAE INTERNATI

39、ONAL AIR4004A Page 7 of 18 Part 25, subpart H, sections 25.1701 through 25.1733 and sections H25.4 and H25.5 (Appendix H) Part 27 Airworthiness Standards: Normal Category Rotorcraft Part 29 Airworthiness Standards: Transport Category Rotorcraft AC 20-53 Protection of Aircraft Fuel Systems against Fu

40、el Vapor Ignition due to Lightning AC 20-136 Protection of Aircraft Electrical / Electronic Systems Against the Indirect Effects of Lightning AC 20-155 SAE Documents to Support Aircraft Lightning Protection Certification AC 20-158 The Certification of Aircraft Electrical and Electronic Systems for O

41、peration in the High Intensity Radiated Fields (HIRF) Environments AC 25-16 Electrical Fault and Fire Prevention Protection AC 25-26 Development of Standard Wiring Practices Documentation AC 25-27 Development of Transport Category Airplane Electrical Wiring Interconnection Systems Instructions for C

42、ontinued Airworthiness Using an Enhanced Zonal Analysis Procedure AC 25.869-1A Fire Protection: Systems AC 25.899-1 Electrical Bonding and Protection Against Static Electricity AC 25.1353-1A Electrical Equipment and Installations AC 25.1357-1A Circuit Protective Device Accessibility AC 25.1360-1 Pro

43、tection Against Injury AC 25.1362-1 Electrical Supplies for Emergency Conditions AC 25.1363-1 Electrical System Tests AC 25.1365-1 Electrical Appliances, Motors, and Transformers AC 25.1701-1 Certification of Electrical Wiring Interconnection Systems on Transport Category Airplanes AC 43.13-1B Accep

44、table Methods, Techniques, and Practices - Aircraft Inspections and Repair AC 65-15A Large Aircraft Airframe and Powerplant Mechanics Handbook ANM-01-04 System Wiring Policy for Certification of Part 25 Aircraft PS-ACE100-2004-10023 Final Policy Statement for Flammability of Electrical Wire used in

45、Part 23 Aircraft per 14 CFR, Part 23, 23.853 and 23.1359 PS-ANM100-2002-00070 Electrical Systems and Equipment PS-ANM111-2002-01-04 System Wiring Policy for Certification of part 25 Airplanes PS-ANM100-1993-00054 Revision of Multiple Burst Lightning Environment SAE INTERNATIONAL AIR4004A Page 8 of 1

46、8 ASW-2001-01 Certification Guidelines for Compliance to the Requirements for Electro-Magnetic Compatibility (EMC) Testing for “Equipment Known to Have a High Potential for Interference” when Installed on Rotorcraft with Electronic Controls that Provide Critical Functions 2.1.8 EASA Publications Ava

47、ilable from European Aviation Safety Agency, Postfach 10 12 53, D-50452 Cologne, Germany, Tel: +49-221-8999-000, www.easa.eu.int. CS-23 Certification Specifications for Normal, Utility, Aerobatic, and Commuter Category Aeroplanes CS-25 Certification Specifications and Acceptable Means of Compliance

48、for Large Aeroplanes CS-27 Certification Specifications for Small Rotorcraft CS-29 Certification Specifications for Large Rotorcraft CS-25 BOOK 1, SUBPART H Electrical Wiring Interconnection System (EWIS) and associated Acceptable Means of Compliance (AMC) 2.2 Definitions Table 1 - Wire insulation a

49、nd tubing material acronym list Acronym Material EPDM Ethylene Propylene Diene Monomer Rubber ETFE Ethylene TetraFluoroEthylene ECTFE Ethylene ChloroTriFluoroEthylene FEP Fluorinated Ethylene Propylene PFA Perfluoro Alkoxy Alkene Polymer PTFE Polytetrafluoroethylene 3. LANDING GEAR ENVIRONMENT The landing gear environment is very severe for electrical wire and cable. The designer should keep in mind that the wire and cable routed on landin