SAE AS 7928 14-2011 TERMINAL ELECTRIC PERMANENT CRIMP STYLE TIN-COATED COPPER INSULATED ENVIRONMENT RESISTANT CLASS 1 150 oC HEATLESS SEALING《150 ℃无热密封1级耐环境的绝缘镀锡铜制压接式永久型电气端子》.pdf

1、AEROSPACE STANDARD TERMINAL, ELECTRIC, PERMANENT, CRIMP STYLE, TIN-COATED COPPER, INSULATED, ENVIRONMENT RESISTANT, CLASS 1, 150 C, HEATLESS SEALING AS7928/14Copyright 2011 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitt

2、ed, 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: +1 724-776-4970 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB

3、 ADDRESS: http:/www.sae.org ISSUED 2011-11THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8C1 FEDERAL SUPPLY CLASS 5970 AS7928/14SHEET 1 OF 5PROCUREMENT SPECIFICATION: AS7928SAE Technical Standards Board Rules provide that: “This report ispublishedby SAE toadvance thestate of technicalandengineering scien

4、ces. Theuse ofthis report is entirely voluntary, andits applicability and suitability forany particular use,including any patent infringement arising therefrom, isthe soleresponsibilityofthe user.”SAE reviews eachtechnicalreport at least every five years at which time itmay bereaffirmed, revised, or

5、cancelled. SAE invites yourwrittencomments andsuggestions. SAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/AS7928/14RATIONALE THIS DOCUMENT PROVIDES THE REQUIREMENTS FOR A ONE PIECE ENVIRONMENT RESISTANT RING TONGUE TERMINAL WITH

6、 A TIN-COATED COPPER TERMINAL ENCASED IN AN ENVIRONMENTAL SLEEVE FILLED WITH A SEALING GEL, WHICH DOES NOT REQUIRE HEAT SHRINK OF THE OUTER SLEEVE. THE TERMINAL TEMPERATURE RATING IS 150 C. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING THE SEALED TERMINAL LUG, DESCRIBED HEREIN SHALL CONSIST OF THIS

7、 DOCUMENT AND THE LATEST ISSUE OF SAE AS7928. FIGURE 1 - HEATLESS SEALED TERMINAL END CAP (COLOR CODE) SEALING MATERIALTERMINAL LUGAG DIA W DIAJ DIA F DIA C RADD0.480r0.020 B REF E DIACONDUCTORVIEWINGWINDOWCopyright SAE International Provided by IHS under license with SAENot for ResaleNo reproductio

8、n or networking permitted without license from IHS-,-,-AEROSPACE STANDARD AS7928/14SHEET 2 OF 5TERMINAL, ELECTRIC, PERMANENT, CRIMP STYLE, TIN-COATED COPPER, INSULATED, ENVIRONMENT RESISTANT, CLASS 1, 150 C, HEATLESS SEALING TABLE 1 CONSTRUCTION DETAILS - INCHES DASH NO.SIZESTUD SIZE AMAX BREF CMINR

9、AD Dr0.002Er0.010DIA FMAX DIA G DIA J MAX DIA W DIA END CAP COLORCODE MAX MIN MAX MIN 00126-204 1.180 0.1650.1710.023 0.145 0.085 0.122 0.114 0.1700.260 0.193 RED 002 6 1.180 0.202 0.152 0.142 0.260 0.245 003 8 1.220 0.202 0.178 0.168 0.330 0.245 004 10 1.220 0.227 0.203 0.193 0.330 0.245 00518-164

10、1.070 0.2400.1250.030 0.178 0.120 0.122 0.114 0.2050.230 0.210 BLUE 006 6 1.250 0.202 0.152 0.142 0.260 0.245 007 8 1.270 0.202 0.178 0.168 0.320 0.305 008 10 1.270 0.234 0.203 0.193 0.473 0.450 009 1/4 1.460 0.265 0.275 0.260 0.473 0.450 010 5/16 1.460 0.296 0.338 0.323 0.473 0.450 011 3/8 1.490 0.

11、328 0.400 0.385 0.540 0.520 012 1.780 0.453 0.525 0.510 0.720 0.705 01314-124 1.080 0.2400.1250.031 0.210 0.155 0.122 0.114 0.2400.260 0.240 YELLOW 014 6 1.150 0.125 0.152 0.142 0.260 0.240 015 8 1.230 0.202 0.178 0.168 0.302 0.317 016 10 1.250 0.202 0.203 0.193 0.302 0.317 017 1/4 1.460 0.265 0.275

12、 0.260 0.473 0.450 018 5/16 1.460 0.296 0.338 0.323 0.473 0.450 019 3/8 1.580 0.328 0.400 0.385 0.540 0.520 020 1/2 1.780 0.453 0.525 0.510 0.720 0.705 NOTES 1. CONDUCTOR VIEWING WINDOW MAY VARY FROM THAT SHOWN 2. CONTOURS MAY VARY FROM THAT SHOWN. 3. UNLESS OTHERWISE INDICATED, DIMENSIONS ARE IN IN

13、CHES (MM). 4. METRIC EQUIVALENTS (TO THE NEAREST 0.1 MM) ARE GIVEN FOR GENERAL INFORMATION AND REFERENCE ONLY. VALUES ARE CALCULATED AND ROUNDED ON 1 INCH = 25.4 MM. 5. DIMENSION “C RAD” REPRESENTS THE MINIMUM WASHER CLEARANCE RADIUS. MATERIALS 1. CRIMP BARREL: COPPER PER ASTM B280, ASTM B75, ASTM F

14、68 OR ASTM B187. 2. METAL FINISH: TIN-PLATED. 3. INSULATION SLEEVE: TRANSPARENT POLYVINYLIDENE FLUORIDE PER SAE-AMS-DTL-23053/8. 4. SEALING MATERIAL: TRANSPARENT CROSSLINKED GEL. 5. END CAPS: THERMOPLASTIC, COLOR CODED PER TABLE 1. Copyright SAE International Provided by IHS under license with SAENo

15、t for ResaleNo reproduction or networking permitted without license from IHS-,-,-AEROSPACE STANDARD AS7928/14SHEET 3 OF 5TERMINAL, ELECTRIC, PERMANENT, CRIMP STYLE, TIN-COATED COPPER, INSULATED, ENVIRONMENT RESISTANT, CLASS 1, 150 C, HEATLESS SEALING REQUIREMENTS 1. CONSTRUCTION: THE TERMINAL ASSEMB

16、LY SHALL CONSIST OF A ONE PIECE ASSEMBLY, WHICH INCLUDES THE SEALING SLEEVE WITH SELF-CONTAINED SEALING MATERIAL, METAL TERMINAL WITH CRIMP BARREL AND COLOR-CODED END CAPS. 2. TERMINAL ASSEMBLY (TRANSPARENT - SLEEVE AND SEALING MATERIAL) SHALL PERMIT VISUAL EXAMINATION OF THE WIRE AS IT IS INSTALLED

17、 IN THE TERMINAL ASSEMBLY. THE TERMINAL LUG END OF THE CRIMP BARREL (VIEWING WINDOW) SHALL BE CLEAR TO VISUALLY DETERMINE THAT THE WIRE IS FULLY INSERTED IN THE TERMINAL LUG. 3. CONTINUOUS OPERATING TEMPERATURE SHALL BE -65 TO +150 C. 4. CRIMPING OF THE TERMINAL SHALL NOT RESULT IN ANY SHARP EDGES W

18、HICH MAY DAMAGE ADJACENT WIRES. 5. ASSEMBLY INSTRUCTIONS: INSTALLATION INSTRUCTION SHALL BE PROVIDED IN EACH PACKAGE OF TERMINALS SHIPPED. 6. QUALIFICATION TESTS SHALL BE IN ACCORDANCE WITH AS7928 QUALIFICATION INSPECTION TABLE EXCEPT AS FOLLOWS: A. GROUP III VIBRATION SHALL INCLUDE AN 18 HOUR THIRD

19、 AXIS (VERTICAL). ANY LEAKAGE OF THE SEALING MATERIAL DURING VIBRATION IN ANY OF THE THREE AXES OF VIBRATION SHALL BE CONSIDERED AS A FAILURE OF THE TERMINAL ASSEMBLY. SAMPLES SHALL PASS ALL REMAINING TESTS IN GROUP V. FIGURE 2 - FIXTURE FOR TEMPERATURE CYCLING TEST AND HEAT AGING B. GROUP VII HEAT

20、AGING: TERMINAL ASSEMBLY SHALL BE MOUNTED VERTICALLY WITH A FILTER PAPER POSITIONED BELOW THE TERMINAL ASSEMBLY (SEE FIGURE 2). ANY LEAKAGE OF THE SEALING GEL AS INDICATED ON THE FILTER PAPER AROUND THE WIRE SHALL BE CONSIDERED AS A FAILURE OF THE TERMINAL ASSEMBLY. WIRE SHALL PENETRATE THE FILTER P

21、APER BY THE OPENING MADE BY A CROSS CUT. LEGS OF THE CROSS SHALL BE APPROXIMATELY EQUAL TO THE OUTER DIAMETER OF THE WIRE SUCH THAT THE PAPER IS IN CONTACT WITH THE WIRE JACKET THROUGHOUT THE TEST. SPECIMENS SHALL BE CONDITIONED FOR A PERIOD OF 500 HOURS. C. ADD GROUP X AND XI. TEST SEQUENCE AND REQ

22、UIREMENTS SHALL BE AS SHOWN ON TABLE 2: FILTER PAPER DIA 3.54 IN (90MM)TERMINAL DIAMETER CRIMPED TERMINAL M22759/11 WIRE Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-AEROSPACE STANDARD AS7928/14SH

23、EET 4 OF 5TERMINAL, ELECTRIC, PERMANENT, CRIMP STYLE, TIN-COATED COPPER, INSULATED, ENVIRONMENT RESISTANT, CLASS 1, 150 C, HEATLESS SEALING TABLE 2 QUALIFICATION INSPECTION INSPECTION REQUIREMENT PARAGRAPH METHOD PARAGRAPH SAMPLE UNITS TYPE I II GROUP X: ALTITUDE IMMERSION (3 CYCLES) IMMERSION (SEAL

24、ING EFFECTIVENESS) ALTITUDE IMMERSION (1 CYCLES) TEMPERATURE CYCLING ALTITUDE IMMERSION (1 CYCLES) MOISTURE RESISTANCE INSULATION RESISTANCE DIELECTRIC WITHSTANDING VOLTAGE VOLTAGE DROP TENSILE STRENGTH -3.5.2.3 (/1) 3.5.3 3.5.1 3.5.7 4.8.6.1 (/1) 4.8.6.2 (/1) 4.8.6.1 (/1) 4.8.6.3 (/1) 4.8.6.1 (/1)

25、4.8.6.4 (/1) 4.8.3 (/1) 4.7.4 4.7.2 4.7.8 - 4 GROUP XI COPPER MIRROR CORROSION 4.6.10.2 (/2) - 1/1 TEST REQUIREMENT AND METHOD OF SAE AS81824 /2 TEST REQUIREMENT AND METHOD OF SAE AMS-DTL-23053 D. ALTITUDE IMMERSION TEST, WATER BATH PREPARATION: IN ADDITION TO THE ANIONIC WETTING AGENT AS SPECIFIED

26、ON SAE AS81824 SPECIFICATION, PARAGRAPH 4.4.3, WATER BASED FLORESCENT TRACER SHALL BE ADDED. AFTER COMPLETION OF THE ALTITUDE IMMERSION TEST, VISUAL INSPECTION SHALL BE PERFORMED TO VERIFY ANY WATER LEAKAGE INTO THE CRIMPED CONNECTION. COLOR CHANGE ON GEL DUE TRACER CONTAMINATION SHALL CONSTITUTE FA

27、ILURE. E. INSULATION RESISTANCE TEST: TEST SPECIMENS SHALL BE PREPARED AS SPECIFIED ON PARAGRAPH 4.7.4 OF SAE AS7928 SPECIFICATION PRIOR TO THE INSULATION RESISTANCE TEST. F. FIFTY SEVEN (57) SAMPLES SHALL BE TESTED FOR EACH TERMINAL SIZE AND DISTRIBUTED IN ACCORDANCE WITH AS7928 QUALIFICATION INSPE

28、CTION TABLE. TERMINAL ASSEMBLIES SHALL BE MADE IN ACCORDANCE WITH THE SUPPLIER ASSEMBLY INSTRUCTIONS WITH M22759/82, M22759/84, M22759/87, M22759/90, OR M22759/92 WIRE. NO ETCHING OR SOLVENT TREATING OF THE ASSOCIATED WIRE INSULATION SHALL BE PERMITTED. HALF THE SAMPLES SHALL BE CRIMPED WITH THE M22

29、520/44-1 TOOL AND HALF WITH THE M22520/5 TOOL WITH /107 OR /108 DIE. SAMPLES SHALL BE DIVIDED EVENLY IN EACH TEST GROUP EXCEPT GROUP I. FOR GROUP 1 SUPPLIER SAMPLE SHALL INCLUDE WITH THE 58 SAMPLES, 24 UNSLEEVED CRIMP BARRELS FOR VERIFICATION OF CRIMP BARREL DIMENSIONS. 7. PART NUMBERS: CONSISTS OF

30、THE LETTER “M”, THE BASIC NUMBER OF THIS SPECIFICATION SHEET, AND A DASH NUMBER TAKEN FROM TABLE 1. EXAMPLE: M7928/14-012 TERMINAL FOR 18-16 WIRE RANGE AND STUD SIZE INCH. 8. IDENTIFICATION OF PRODUCT MARKING MANUFACTURER IDENTIFICATION AND PART NUMBER MARKING SHALL BE AS SPECIFIED IN AS7928, WHEN L

31、IMITED BY MARKING SPACE, THE PACKAGE SHALL BE MARKED WITH PART NUMBER AND MANUFACTURES IDENTIFICATION AT A MINIMUM. TOOLING 1. CRIMPING TOOL: IN ACCORDANCE WITH TABLE 3. TABLE 3 CRIMP TOOLS .TERMINAL PART NO. CRIMP TOOL NO. DIE TYPE CRIMP TOOL NO. DIE NO. M7928/14-1 THRU -8 M22520/44-01 M22520/5-01

32、M22520/5-107 M7928/14-9 THRU -16 M22520/44-01 M22520/5-01 M22520/5-107M7928/14-17 THRU -24 M22520/44-01 M22520/5-01 M22520/5-108 Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-AEROSPACE STANDARD AS7

33、928/14SHEET 5 OF 5TERMINAL, ELECTRIC, PERMANENT, CRIMP STYLE, TIN-COATED COPPER, INSULATED, ENVIRONMENT RESISTANT, CLASS 1, 150 C, HEATLESS SEALING APPLICATION NOTES 1. WARNING: DO NOT APPLY HEAT TO THIS TERMINAL. APPLICATION OF HEAT (IN EXCESS OF 150 C) TO THIS TERMINAL WILL PERMANENTLY DAMAGE THE

34、PRODUCT. IF HEATED (IN EXCESS OF 150 C), THE TERMINAL MUST BE REPLACED. 2. TERMINAL MAY BE USED IN APPLICATIONS WHERE AS7928/4 TERMINALS ARE USED IF DIMENSIONAL DIFFERENCES DO NOT IMPACT THE FIT. 3. INTENDED USE A. TERMINAL IS INTENDED FOR USE IN MAKING ENVIRONMENTALLY PROTECTED PERMANENT TERMINATIO

35、N USING ONE WIRE WITHIN THE DIAMETER RANGE SPECIFIED IN THIS SPECIFICATION WITHOUT THE APPLICATION OF HEAT (HEATLESS INSTALLATION). B. CRIMPING OF THIS DEVICE IS INTENDED TO BE PERFORMED OVER THE INSULATION TUBING. CRIMPING WIRES INTO THE TERMINAL IS PERFORMED WITHOUT REMOVING THE INSULATION SLEEVE.

36、 THE TERMINAL IS LOADED INTO THE DESIGNATED CRIMP TOOL AND CRIMPED ON THE INSULATION SLEEVE. 4. TERMINAL MAY BE USED WITH TIN, NICKEL OR SILVER PLATED COPPER CONDUCTORS, WHICH ARE WITHIN THE WIRE RANGE AS INDICATED IN THIS SPECIFICATION. THE APPLICATION SHOULD NOT EXCEED THE 150 C RATING OF THE TERM

37、INAL. 5. REFER TO SUPPLIERS INSTALLATION INSTRUCTIONS FOR INSTALLING DETAILS. 6. COLOR CODED WIRE STRIP LENGTH REFERENCE SLOT IS INCLUDED ON DESIGNATED CRIMP TOOLS MEETING AS22520/44. DETAILS OF THIS TOOL ARE SPECIFIED IN SAE AS81824/12. Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-