ASD-STAN PREN 2242-2011 Aerospace series Crimping of electric cables with conductors defined by EN 2083 EN 4434 and EN 2346 (Edition P 2).pdf

1、ASD-STAN STANDARD NORME ASD-STAN ASD-STAN NORM prEN 2242 Edition P 2 July 2011 PUBLISHED BY THE AEROSPACE AND DEFENCE INDUSTRIES ASSOCIATION OF EUROPE - STANDARDIZATIONAvenue de Tervuren, 270 - B-1150 Brussels - Tel. 32 2 775 8126 - Fax. 32 2 775 8131 - www.asd-stan.orgICS: Supersedes edition P 1 of

2、 October 1991 Descriptors: ENGLISH VERSION Aerospace series Crimping of electric cables with conductors defined by EN 2083, EN 4434 and EN 2346 Srie arospatiale Sertissage des cbles lectriques avec conducteurs dfinis par EN 2083, EN 4434 et EN 2346 Luft- und Raumfahrt Crimpen von elektrischen Leitun

3、gen mit Leitern nach EN 2083, EN 4434 und EN 2346 This “Aerospace Series“ Prestandard has been drawn up under the responsibility of ASD-STAN (The AeroSpace and Defence Industries Association of Europe - Standardization). It is published for the needs of the European Aerospace Industry. It has been t

4、echnically approved by the experts of the concerned Domain following member comments. Subsequent to the publication of this Prestandard, the technical content shall not be changed to an extent that interchangeability is affected, physically or functionally, without re-identification of the standard.

5、 After examination and review by users and formal agreement of ASD-STAN, it will be submitted as a draft European Standard (prEN) to CEN (European Committee for Standardization) for formal vote and transformation to full European Standard (EN). The CEN national members have then to implement the EN

6、at national level by giving the EN the status of a national standard and by withdrawing any national standards conflicting with the EN. Edition approved for publication 1 July 2011 Comments should be sent within six months after the date of publication to ASD-STAN Electrical Domain Copyright 2011 by

7、 ASD-STAN prEN 2242:2011 (E) 2 Contents Page Foreword 2 1 Scope 3 2 Normative references 3 3 Terms and definitions .4 4 General requirements for crimping 4 5 Tooling 4 6 Procedures .5 7 Quality assurance 7 Annex A (normative) Correct crimped connections 8 Annex B (normative) Faulty crimped connectio

8、ns (examples) 9 Foreword This standard was reviewed by the Domain Technical Coordinator of ASD-STANs Electrical Domain. After inquiries and votes carried out in accordance with the rules of ASD-STAN defined in ASD-STANs General Process Manual, this standard has received approval for Publication. prE

9、N 2242:2011 (E) 3 1 Scope This standard specifies the general requirements and procedures to ensure the good quality of crimped connections made with multi-stranded cables with conductor cross-sections ranging from 0,15 mm2(AWG 26) to 107 mm2(AWG 0000) and all types of connection components 1). Elec

10、tric cables to be used for the tests shall conform to EN 2084, EN 2234, EN 2235, EN 2346 and be stripped according to EN 2812. For conductors see EN 2083, EN 4434 and EN 2346. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated

11、references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 2083, Aerospace series Copper or copper alloy conductors for electrical cables Product standard EN 2084, Aerospace series Cables, electric, single-

12、core, general purpose, with conductors in copper or copper alloy Technical specification EN 2234, Aerospace series Cable, electrical, fire resistant Technical specification 2)EN 2235, Aerospace series Single and multicore electrical cables, screened and jacketed EN 2346, Aerospace series Fire resist

13、ant electrical cables Dimensions, conductor resistance and mass EN 2591-417, Aerospace series Elements of electrical and optical connection Test methods Part 417: Tensile strength (crimped connection) EN 2591-503, Aerospace series Elements of electrical and optical connection Test methods Part 503:

14、Contact deformation after crimping EN 2812, Aerospace series Stripping of electrical cables EN 3155-002, Aerospace series Electrical contacts used in elements of connection Part 002: List and utilization of contacts EN 4434, Aerospace series Copper or copper alloy lightweight conductors for electric

15、al cables Product standard (Normal and tight tolerances) IEC 60050-581, International Electrotechnical Vocabulary Part 581: Electromechanical components for electronic equipment3)1) Barrel, terminal lug, splice. 2) Published as ASD-STAN Prestandard at the date of publication of this standard (www.as

16、d-stan.org). 3) Published by: IEC International International Electrotechnical Commission http:/www.iec.ch/. prEN 2242:2011 (E) 4 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 crimping mechanism mechanism controlling the total crimping cycl

17、e; fitted with a device which prevents the tool from returning to open position before the completion of this cycle 3.2 test piece consists of a length of terminated cable For further definitions see IEC 60050-581. 4 General requirements for crimping The cable cross-section shall be compatible with

18、the crimp barrel and be within the limits defined in the specification for connectors, connection components and tooling being used. It shall be verified that the combination “conductor - crimp tool - crimp barrel“ complies with the requirements of the wiring and has been qualified by the responsibl

19、e authorities. The crimping of the conductor shall be carried out in a single operation with the aid of the appropriate tooling approved by the manufacturer of the connection components. This operation shall not require any additional heating or cooling. No additional operation such as brazing, etc.

20、 shall be carried out on a crimped connection. The organization and preparation of the work area shall be such that: the tooling is constantly maintained in good condition; a check can be made that only the tools and accessories adapted to this type of crimping are used; there have been no adjusteme

21、nts to the tooling. During handling and transport, the crimped connections shall not be subjected to any stress likely to cause deterioration. 5 Tooling The crimping tools and their accessories shall be approved by the responsible authorities. prEN 2242:2011 (E) 5 6 Procedures 6.1 General Before man

22、ufacturing, test pieces shall be prepared for each combination “conductor - crimp tool - crimp barrel“ to be tested to qualify the crimping process. 6.2 Checking of tooling 6.2.1 Stripping tool Before stripping, ensure that the stripping tool has been inspected and meets the requirements of EN 2812.

23、 6.2.2 Crimping tool Ensure that the crimping tool has been inspected and that the crimping mechanism is functioning correctly. 6.3 Preparation of test pieces The test pieces shall be tracable to the electrical cable they represent. 6.4 Inspection prior to crimping Check that the connection componen

24、ts and the cable conform to the definition documentation. In addition to the general requirements (see Clause 4), the connection components shall be clean, free from any trace of corrosion and shall not show any defects. However, a uniform and superficial discoloration is tolerated. The cable shall

25、be stripped in accordance with EN 2812. Crimping of multiple conductors In the case of crimping two conductors in one connection component, the following conditions shall be observed: the sum of the two actual sections of the conductors shall be compatible with the section permitted by the connectio

26、n component; the stripping lengths of the cable ends shall be identical; all the strands of the two conductors, placed parallel to each other, shall enter easily into the connection component; the crimping operation shall not cause any offset of one conductor in relation to the other; the tensile st

27、rength of the crimped connection of each conductor shall conform to the minimum tensile strength value defined for the cross-section of that conductor in Table 1, when tested in accordance with EN 2591-417. 6.5 Crimping The test pieces shall be made only with the connection components and under the

28、specified manufacturing conditions. Each end of the test piece shall be fitted with an identical barrel. prEN 2242:2011 (E) 6 6.6 Tests after crimping 6.6.1 General They shall be carried out on five test pieces of the minimum conductor cross-section and five test pieces of the maximum conductor cros

29、s-section. These tests shall be repeated if one of the following conditions changes: material of strands of the conductors; metallic covering of strands : tin plating, silver or nickel plating, etc.; size of connection components; types of tools used, with corresponding accessories. 6.6.2 Visual ins

30、pection It shall be carried out on all test pieces see Annex A (normative) and Annex B (normative): Ensure that: the form and location of the crimps are correct, see Figure A.1, Figure A.2 and Figure A.3; the stripping length is correct and that the strands of the conductor are all correctly inserte

31、d in the barrel (conductor visible through the inspection hole), see Figure A.3; the distance between the insulation of the cable and the barrel is such that no bending of the cable can exert stress in the area of the barrel, see Figure A.2; the conductor at the rear of the barrel is not deformed, s

32、ee Figure A.2; the connection component shows no defects and no burr, sharp edge, crack or lift off of the protection, or distortions according to EN 2591-503. Requirement: if the inspection is not satisfactory, the crimping process shall be revised. 6.6.3 Tensile test Each test piece which has sati

33、sfied the visual inspection shall be submitted to the tensile strength test according to EN 2591-417. Insulation grip shall be rendered ineffective, before the test is carried out. Requirement: if one of the crimped connections fractures at a value lower than that specified in Table 1, the crimping

34、process shall be reviewed. prEN 2242:2011 (E) 7 Table 1 Nominal sections of conductors AWG a Nominal contact size b Minimum tensile strength of crimped connections mm2N 0,15 c 26 39 0,25 c 24 550,40 22 60 0,60 20 901,00 18 b20 1201,00 18 150 1,20 16 1802,00 14 300 3,00 12 4505,00 10 700 9,00 8 1 080

35、14,00 6 540 22,00 4 1 98034,00 2 2 720 42,00 1 3 20053,00 0 4 200 68,00 00 5 30085,00 000 6 400 107,00 0000 8 400 aAWG American Wire Gage. bFor enlarged contact barrel, see EN 3155-002. cHigh strength copper alloy conductors. 7 Quality assurance 7.1 Production controls Visual inspection of all crimp

36、ed connections, requirements as defined in 6.6.2. 7.2 Periodic inspections According to the number of crimped connections to be manufactured and/or the quality requirements, the responsible authority can check the points enumerated in 6.6.2 and 6.6.3, between 1 000 crimps and 5 000 crimps, or each q

37、uarter, with at least two test pieces of the minimum conductor cross-section and at least two test pieces of the maximum conductor cross-section. Notwithstanding the values specified in Table 1, the tensile strength test may be limited to 500 N for all sections equal to or greater than 5 mm2, if aut

38、horized by the responsible authority, when carrying out periodic qualification tests on crimping tools. prEN 2242:2011 (E) 8 Annex A (normative) Correct crimped connections Figure A.1 Figure A.2 Key 1 Inspection hole Figure A.3 Checks to be carried out: strands apparent in the inspection hole; corre

39、ct stripping of insulator; insulator correctly positioned; indentation correctly positioned; non-distorted contacts; no cracks or lift off of protection. prEN 2242:2011 (E) 9 Annex B (normative) Faulty crimped connections (examples) Insulation stripping too long Insulation stripping too short and cr

40、imping on the insulator Conductor stripping too short Strands crimped with the insulation supportOne or more strands of the conductor not crimped Insulation stripping too short the insulation penetrates into the barrel Insulation stripping too short the conductor not visible through the inspection hole Insulation stripping too long Incorrect position of the crimping indentorsFigure B.1