SAE AS 60491-2015 Sleeve Protection For Cable and Harness Protection.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 ther

2、efrom, 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

3、publication 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: +1 724-776-49

4、70 (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/AS60491 AEROSPACE STANDARD AS60491 Issued 2015-12 Sleeve, Protection, For Cable

5、and Harness Protection RATIONALE Procurement specification required to standardize protection sleeves presently procured by supplier part numbers. 1. SCOPE (SEE 6.1) Procurement specification is principally for defining protection sleeves on a cable or group of electrical/fiber optic wires (wiring b

6、undle). Single wire protection depends on the minimum diameter of the wire. Sleeve may be used to protect a wire bundle for a platform installation or for repair of installed damaged jacket or jacket/shielded wire bundles. See AS50881 for aerospace wire bundle protection installations. 1.1 Temperatu

7、re Operation Range The sleeve temperature range is -60 to +175 C/+200 C/+240 C/+260 C depending on material and is defined in the detail specification. Mechanical properties may be reduced with increasing temperature. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of t

8、his document to the extent specified herein. The latest issue of SAE publications 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 o

9、f this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.2 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and C

10、anada) or +1 724-776-4970 (outside USA), www.sae.org. AMS1424 Deicing/Anti-Icing Fluid, Aircraft SAE Type 1 AIR1351 Manufacturers Identification of Aerospace Electrical and Electronic Wiring Devices and Accessories AS4373 Test Methods for Insulated Electric Wire AS9100 Quality Management Systems - R

11、equirements for Aviation, Space and Defense Organizations AS50881 Wiring Aerospace Vehicle SAE INTERNATIONAL AS60491 Page 2 of 22 AS60491/1* Sleeve, Chafe-protection, Wrap-Around, Self-closing (-55 to +200C) AS60491/2* Sleeve, Chafe-protection, Wrap-Around, Self-closing, High Temp (-55 to +260C) AS6

12、0491/3* Sleeve, Chafe-protection, Expandable (-55 to +200C) AS60491/4* Sleeve, Chafe-protection, High Abrasion, Expandable (-55 to +200C) AS60491/5* Sleeve, Chafe-protection, Expandable (-55 to +240C) AS60491/6* Sleeve, Chafe-protection, Wrap-Around, Self-closing (-55 to +175C) AS60491/7* Sleeve, Ch

13、afe-protection, Wrap-Around, Self-closing, Shielded, (-55 to +200C) EIA-557 Statistical Process Control Systems SAE J2192 Recommended Testing Methods for Physical Protection of Wiring Harnesses *AS60491 detail specification 2.3 U.S. Government Publications Copies of these documents are available onl

14、ine at http:/quicksearch.dla.mil. MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-DTL-83133 Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO F-434), NATO F-35, and JP-8+100 (NATO F-37) MIL-PRF-5606 Hydraulic Fluid, Petroleum Base, Aircraft, Missile, and Ordinance MIL-PRF-7808 Lubricat

15、ing Oil, Aircraft Turbine Engine, Synthetic Base MIL-PRF-23699 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base, NATO Code Numbers: O-152, O-154, O-156, and O-167 MIL-PRF-87937 Cleaning Compound, Aerospace Equipment SD-6 Provisions Governing Qualification 2.4 NCSL Publications Available from

16、 NCSL International, 2995 Wilderness Place, Suite 107, Boulder, CO 80301, Tel: 303-440-3339, www.ncsli.org. NCSL Z540.3 Requirements for the Calibration of Measuring and Test Equipment 2.5 ASQ Publications Available from American Society for Quality, 600 North Plankinton Avenue, Milwaukee, WI 53203,

17、 Tel: 800-248-1946 (United States or Canada), 001-800-514-1564 (Mexico) or +1-414-272-8575 (all other locations), www.asq.org. ANSI/ASQ Z1.4 Sampling Procedures and Tables for Inspection by Attributes SAE INTERNATIONAL AS60491 Page 3 of 22 2.6 ASTM Publications Available from ASTM International, 100

18、 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM A686 Standard Specification for Tool Steel, Carbon ASTM B355 Standard Specification for Nickel-Coated Soft or Annealed Copper Wire ASTM D3032 Standard Test Methods for Hookup Wire Insulation 2.

19、7 NEMA Publications Available from National Electrical Manufacturers Association, 1300 North 17th Street, Suite 900, Arlington, VA 22209, Tel: 703-841-3200, www.nema.org. WC 27500 Standard for Aerospace and Industrial Electric Cable 2.8 IEC Publications Available from IEC Central Office, 3, rue de V

20、arembe, P.O. Box 131, CH-1211 Geneva 20, Switzerland, Tel: +41 22 919 02 11, www.iec.ch. IEC 61000-4-21 Testing and measurement techniques Reverberation chamber test methods 2.9 Other Government Documents The following other government document forms a part of this specification to the extent specif

21、ied herein. Unless otherwise specified, the issue shall be the one in effect on the date of the solicitation. FEDERAL AVIATION ADMINISTRATION Available from http:/www.ecfr.gov/ AIRWORTHINESS STANDARDS Part 25 - Transport Category Aircraft DEFENSE LOGISTICS AGENCY H4/H8 Catalog of Commercial and Gove

22、rnment Entities (CAGE) (Copies of specifications, standards and other government documents required by contractors in connection with specific acquisition functions should be obtained from the contracting activity or as directed by the contracting activity.) 3. REQUIREMENTS 3.1 Detail Specification

23、(see 2.1) The product requirements shall be as specified herein and in accordance with the applicable detail specification. In the event of any conflict between the requirements of this specification and the detail specification, the latter shall govern. Metric units shall be shown in parentheses. 3

24、.2 Qualification The components shall be a product that has been tested and has passed the qualification tests specified herein, and has been listed on or approved for listing on the applicable Qualified Products List (see 6.3). SAE INTERNATIONAL AS60491 Page 4 of 22 3.3 Materials (see 5.1.1) Materi

25、als shall be specified and listed in the detail specification in accordance with a material specification. Materials shall be certified by the supplier. Additives are permitted by the supplier, but shall be strictly controlled by engineering and manufacturing process control procedures. The procedur

26、e control numbers with the latest revision and a generic title shall be available to the Qualifying Activity upon request (see 6.3). Only mold resistance materials shall be used and shall be certified by supplier. 3.4 Component Design and Construction 3.4.1 Design (see 6.2) 3.4.1.1 Sleeve Design Sle

27、eve shall be designed to expand or wrap-around a cable or wire bundle to provide protection against chaffing. Unless otherwise specified in the detail specification, each sleeve shall be built-up of groups of monofilament or multifilament fibers made from the same material or combinations of materia

28、ls. 3.4.1.1.1 Expandable Sleeve Expandable sleeve shall be a tubular braid construction capable of expanding to fit different cable or wire bundle shapes and sizes. The range of sizes shall be specified in the detailed specification. The sleeve is a tubular braid which may require the removal of the

29、 cable or bundle from which it is installed. 3.4.1.1.2 Wrap-Around sleeve Sleeve shall be designed to wrap around a cable or wire bundle without complete removal of the cable or bundle from the equipment in which it is installed. The sleeve shall be self-closing or the closing system shall have a lo

30、cking device (i.e., lacing tape). The self-closing sleeve shall have tracer line which acts as a maximum diameter indicator. The tracer line should not be visible along the leading edge when wrapped on the largest diameter cable or bundle specified by the part number. If the tracer line is visible,

31、the next larger sleeve diameter should be used. For protection sleeve with a shield, the shield shall be attached to inside edge of the sleeve and shall not be exposed to the leading edge of the sleeve. This sleeve requires a nominal 90 degree overlap of material to ensure protection and prevent cre

32、ating a foreign object damage in aerospace vehicle applications. Wraparound sleeve sizing is based on the nominal size of the wire bundle, determined by wrapping the material around the bundle and ensuring a nominal 90 degree overlap. 3.4.1.2 The braid of the fibers (when applicable) and metallic st

33、rands shall be specified in the detail specification (see 3.4.4). 3.4.1.3 When used, coating materials shall be specified in the detail specification (see 3.3). 3.4.2 Dimensions (see 5.1.2) Dimensions and overlap angle shall be in accordance with the detail specification. 3.4.3 Weight (see 5.1.3) Th

34、e weight of the sleeve per unit length shall be specified in the detail specification. 3.4.4 Sleeve and Shield Coverage (see 5.1.4) Unless otherwise specified in the detail specification, the sleeve braid of the fiber (when applicable) and the metallic shield strand coverage shall be 85% minimum, or

35、 as defined in the detail speciation sheet. SAE INTERNATIONAL AS60491 Page 5 of 22 Sleeve braid shall be applied with the maximum tension possible so as to prevent loosening or creeping but not to cause broken ends. Braid shall have no gaps. Loose strand ends shall be trimmed to within 0.031 inch (0

36、.79 mm) of the weave and shall lay parallel with the braid. There shall be no splices of the completed braid. The number of braids and the elements of their construction shall be as specified in the detail specification (see 3.1). The percent coverage specified shall be determined In accordance with

37、 the formulas shown below. Weave or shield coverage = (2F F2) X 100% where: W = Maximum width of braid laid flat d = Diameter of an individual strand of the braid N = Number of ends (fiber or wire strands) per carrier C = Number of carriers (separated group of ends) around the diameter of the braid

38、P = Minimum number of picks per inch (separation points between carriers) along the length of the braid a = Smaller angle between longitudinal axis of the cable and the braid strands or wires F = Fill or space factor Figure 1 - Sleeve fabric or wire braid 3.4.4.1 Sleeve coverage - braided tubular (s

39、ee 5.1.4.1) 3.4.4.2 Sleeve overlap - woven wrap-around sleeves (see 5.1.4.2) NPd Sin a F = a = tan-12 (W+2 G 3 C d SINGLE STRAND DIAMETER W SAE INTERNATIONAL AS60491 Page 6 of 22 3.4.5 Product Identification and Marking (see 5.1.5) 3.4.5.1 Product Identification The product identification shall be d

40、efined by the sleeve color and identification stripe. Unless otherwise specified in the detail specification, the sleeve color number shall be in accordance with Table 1. Part number structure is as follows: AS60491/X XX XX Sleeve Color Code (see Table 1) Sleeve Size Code (see detail specification)

41、Detail Specification Specification Number Table 1 - Color code numbers Color Number Color Color Number Color 0 BLACK 6 BLUE 1 BROWN 7 PURPLE 2 RED 8 GRAY 3 ORANGE 9 WHITE (or NATURAL) 4 YELLOW 57 GREEN/PURPLE 5 GREEN 3.4.5.2 Wrap-Around Sleeve Tracer Line A tracer line shall run continuously along t

42、he axis of the sleeve. The tracer line color should be a contrasting color to the main sleeve color; i.e., black sleeve use a white tracer line. For specific cable or bundle type applications (i.e., high temperature, fiber optic, etc.) a stripe with identification colors may be used. The identificat

43、ion stripe color and width shall be defined in the detail specification. The location of the tracer line shall defined by the angle of overlap in the detailed specification. Figure 2 - Tracer line and identification stripe location Tracer Line/maximum diameter indicator Identification Stripe LOverla

44、pangleSAE INTERNATIONAL AS60491 Page 7 of 22 3.4.5.3 Marking Unless otherwise specified in the detail specification sheet, the sleeve shall be identified by a printed marking applied to the outer surface of the sleeve. The identification mark shall not be applied by hot stamp marking or other method

45、s which significantly penetrate the sleeve material. The printed identification shall consist of the following; the sleeve part number as specified in the detail specification sheet, except that inclusion of the color code portion of the part number is not required in the printed marking along with

46、the manufacturers Commercial and Government Entity (CAGE) designation in accordance with Publication H4/H8. The printed marking shall be at intervals of 6 to 18 inches, as measured from the end of one complete marking to the beginning of the succeeding complete marking. The printing shall be of a co

47、lor to provide contrast to the sleeve color. Identification printing shall be applied with the vertical axes of the printed characters lengthwise of the sleeve. All printed characters shall be complete and legible. 3.4.6 Product Identification and Marking Durability (see 5.1.6) The product Identific

48、ation, tracer line and stripe shall not be obliterated after subjection to the durability and legibility of wire identification test unless otherwise specified in the detail specification sheet. 3.4.7 Assembly Instruction (see 5.1.7) When specified by contract or purchase order, assembly instruction

49、s are required with each package spool (see Section 6). 3.4.8 Workmanship (see 5.1.8) Sleeve shall be uniform throughout the construction, free from splits, foreign material, or defects that affect the serviceability of the sleeve in the installed condition. There shall be no significant fraying of the fiber or shield strands, holes or irregularity in the fiber or metallic strand braid. T