1、BRITISH STANDARD BS4G 178-2: 1986 Crimped joints for aircraft electrical cables and wires Part 2: Specification for control of crimping (including user control tests) UDC 629.7.064.5:621.315.687BS4G 178-2:1986 This British Standard, having been prepared under the directionof the Aerospace Standards
2、Committee, was published under the authority ofthe Board of BSI and comesintoeffect on 28 November 1986 BSI 07-1999 First published March 1972 First part revision as BS G 178-1 August 1984 First part revision as BS G 178-2 November 1986 The following BSI references relate to the work on this standar
3、d: Committee reference ACE/6 Draft for comment 81/71694 DC ISBN 0 580 14957 9 Committees responsible for this British Standard The preparation of this British Standard was entrusted by the Aerospace Standards Committee (ACE/-) to Technical Committee ACE/6, upon which the following bodies were repres
4、ented: BEAMA Ltd. British Rubber Manufacturers Association Civil Aviation Authority Electric Cable Makers Confederation Electronic Components Industry Federation Electronic Engineering Association Ministry of Defence National Supervising Inspectorate Society of British Aerospace Companies Ltd. Amend
5、ments issued since publication Amd. No. Date of issue CommentsBS4G178-2:1986 BSI 07-1999 i Contents Page Committees responsible Inside front cover Foreword ii 1 Scope 1 2 Performance of crimped joints 1 3 Routine inspection 1 4 Quality control inspection and testing 1 Appendix A Tests on crimped joi
6、nts 2 Appendix B Inspection of tools and dies 2 Figure 1 Light current applications. Wire cross-sectional area up to 5 mm 2(105 C and 135 C categories) 3 Figure 2 Light current applications. Wire cross-sectional area up to 5 mm 2(190 C and 260 C categories) 4 Figure 3 Power applications. Wire cross-
7、sectional area from 5 mm 2to 106 mm 2(105 C and 135 C categories) 5 Figure 4 Power applications. Wire cross-sectional area from 5 mm 2to 106 mm 2(190 C and 260 C categories) 6 Table 1 Pull-off loads, test currents and voltage drop values for copper andcopper alloy conductor crimps 7 Publications ref
8、erred to Inside back coverBS4G 178-2:1986 ii BSI 07-1999 Foreword This Part of BS 4G 178, prepared under the direction of the Aerospace Standards Committee, provides details of the requirements of aircraft constructors and operators for crimping connections for electrical cables for aircraft. The st
9、andard is published in separate Parts: Part 1 relates to the design requirements and tests for the manufacture of terminal ends, connector contacts, cable splices and their associated crimping tools and Part 2 relates to user control tests for crimped joints. BS4G178-1 and BS4G178-2 together form a
10、complete revision of BS3G178:1978, which is withdrawn. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal
11、 obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages1 to 8, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table
12、 on theinside front cover.BS4G178-2:1986 BSI 07-1999 1 1 Scope This Part of BS 4G 178 gives user control tests for aircraft constructors or operators when crimping connections for electrical cables for aircraft. NOTEThe titles of the publications referred to in this standard are listed on the inside
13、 back cover. 2 Performance of crimped joints When tested in accordance with Appendix A, the value of voltage drop across each joint shall not exceed the appropriate value given in the relevant curve from Figure 1, Figure 2, Figure 3 or Figure 4. NOTEShould the relevant approving authority decide tha
14、t the user has shown an adequate alternative measure of quality control, the authority may require only the tensile test to be implemented. When tested in accordance with Appendix A, the pull-off load, applicable to all temperature ranges, shall not fall below the minimum value given in the relevant
15、 curve from Figure 1 or Figure 3. 3 Routine inspection Every crimped joint shall be visually inspected for: a) correct combination of cable, tool and terminal end, connector contact or cable splice; b) correct die mark, where applicable; c) correctness of form and location of crimp; d) freedom from
16、fracture, rough or sharp edges and flash; e) adequate insertion of all conductor strands in the crimping barrel; f) absence of damage to the conductor or insulation. NOTECertain visual inspections may require a degree of optical magnification to ensure compliance with the stated criteria. 4 Quality
17、control inspection and testing Unless otherwise specified by the Inspecting Authority, tools and dies and the crimped joints being produced by them shall be inspected and tested in accordance with Appendix A and Appendix B as follows: a) at the beginning of the use of any tool or die; and b) at the
18、beginning of the use of any tool or die that has been stored without use for a period of longer than three months; and c) at three-monthly intervals throughout the period of use of any tool or die or at intervals of2000 crimps per tool or die, whichever interval is the shorter. NOTEThe Inspecting Au
19、thority may vary the periodicity of testing in the light of experience. Joints shall be crimped using tools in accordance with BS 4G178-1:1984.BS4G178-2:1986 2 BSI 07-1999 Appendix A Tests on crimped joints A.1 Preparation of specimens A.1.1 Prepare the specimens as follows. a) For terminal ends. A
20、length of cable with a terminal at each end. b) For cable splices. Lengths of cable joined by in line or parallel splices. c) For connector contacts. A length of cable with a connector contact at each end. NOTEWhen agreed by the Inspecting Authority single-ended specimens may be used for the tensile
21、 and voltage drop tests. Care should be taken to ensure repeatability of readings when using probes or weighted knife edges. Where results recorded on single-ended specimens are marginal, the tests should be cross-checked on double-ended specimens. A.1.2 Take the required cable and components from p
22、roduction. A.1.3 Use a cable of at least 150 mm in length, measured, before crimping, between the points where the conductors will enter the respective conductor crimping barrels. Strip the cable ends of insulation in accordance with the cable manufacturers recommendations, taking care not to sever
23、or damage any strands. Remove all insulation from the stripped portion of the conductor. After stripping, leave the end of the insulation clean and square. Should the lay of the strands be disturbed, reimpose it by a light twist. Ensure that the conductor is clean before assembly with the terminal e
24、nd, connector contact or splice. NOTECables should be severed using a tool with a single stroke cutting device. A.2 Number of specimens For the voltage drop test (seeA.3), prepare six specimens of each and every combination of crimped barrel, conductor, tool, die, indentor or positioner used in prod
25、uction. For the tensile test (seeA.4), prepare at least two specimens of each and every combination of crimped barrel, conductor, tool, die, indentor or positioner used in production. NOTEUndamaged specimens from the voltage drop test may be utilized for the tensile test. A.3 Voltage drop test Pass
26、the test current given by the appropriate curve from Figure 1, Figure 2, Figure 3 or Figure 4 at an open circuit voltage of not greater than30V through the specimen. Use measuring instruments complying with class index 1.0 of BS89. For terminations other than connector contacts, measure the voltage
27、drop between the intersection of one palm and barrel and the corresponding point on the other terminal, taking care to avoid contact with the conductor strands. For connector contacts, take the measurement between the intersection of the shoulder and the crimped barrel of the contacts. For cable spl
28、ices, take the measurement between the mid points of the two consecutive splices. Determine the voltage drop across each joint by taking one half of that ascertained by subtracting from the overall drop the voltage drop attributable to the length of included cable (i.e. at least150mm) measured on no
29、t less than3m of cable taken from the same production reel as that used for the test specimens. NOTE 1Care is necessary to ensure that the conductor temperature remains constant for successive readings. NOTE 2For users employing cables with conductors in accordance with BS G231, Table 1 is included.
30、 This table gives a quick reference to required initial millivolt drop values and tensile pull-off values for these conductors. The table is identical to Table 1 of BS 4G 178-1:1984 but is reproduced here for the convenience of users not concerned with type testing. A.4 Tensile test Test the specime
31、n in a tensile machine in which an axial pull is applied and in which the jaws separate at a steady rate of between25mm/min and50mm/min. Appendix B Inspection of tools and dies Inspect tools and dies to verify that they comply with the gauging requirements of the tool manufacturer and that they will
32、: a) correctly locate and control the position of the crimp on the barrel; b) not release the terminal during normal operation until the conductor crimp has been correctly formed; c) not axially deform connector contacts or increase the effective diameter along the length of the crimped section by m
33、ore than the amounts specified in the connector or contact specification; d) during the formation of the conductor crimp, apply the appropriate mark, where required, to indicate the die size or tool which has been used; e) not adversely affect the external protective treatment or insulation during t
34、he crimping operation; f) not fracture the terminal end or cause any rough or sharp edges or flash.BS4G178-2:1986 BSI 07-1999 3 Figure 1 Light current applications. Wire cross-sectional area up to 5 mm 2(105 C and 135C categories)BS4G178-2:1986 4 BSI 07-1999 Figure 2 Light current applications. Wire
35、 cross-sectional area up to 5 mm 2(190 C and 260 C categories)BS4G178-2:1986 BSI 07-1999 5 Figure 3 Power applications. Wire cross-sectional area from 5 mm 2to 106 mm 2(105 C and135 C categories)BS4G178-2:1986 6 BSI 07-1999 Figure 4 Power applications. Wire cross-sectional area from 5 mm 2to 106 mm
36、2(190C and260 C categories)BS 4G 178-2:1986 BSI 07-1999 7 Table 1 Pull-off loads, test currents and voltage drop values for copper and copper alloy conductor crimps Conductor Test currents and voltage drop per crimped joint Pull-off load Maximum temperature of cables Conductor size Number and nomina
37、l diameter of wires Maximum diameter Cross-section area CMA 105 C 135 C 190 C 260 C Test current Voltage drop (max.) Test current Voltage drop (max.) Test current Voltage drop (max.) Test current Voltage drop (max.) mm mm 2 A mV A mV A mV A mV N 26 24 22 20 18 16 14 12 10 8 6 4 2 1 0 00 000 0000 19/
38、0.10 19/0.12 19/0.15 19/0.20 19/0.25 19/0.30 37/0.25 37/0.32 37/0.40 119/0.30 182/0.30 294/0.30 203/0.45 245/0.45 322/0.45 420/0.45 518/0.45 665/0.45 0.53 0.62 0.80 1.04 1.29 1.53 1.82 2.28 2.88 4.40 5.50 6.80 8.60 9.50 10.70 12.10 13.60 15.20 .149 .215 .336 .597 .933 1.340 1.820 2.980 4.650 8.410 1
39、2.860 20.780 32.290 38.970 51.210 66.800 82.380 105.760 285/305 410/438 628/698 1131/1225 1841 2645 3592 5881 9177 16597 25380 41010 63725 76908 101064 131831 162579 208720 4.0 7.0 11.0 14.0 18.0 20.0 30.0 40.0 60.0 85.0 110.0 150.0 200.0 220.0 240.0 260.0 280.0 300.0 9 9 8 7 7 7 6 6 5 5 5 5 5 5 4 4
40、 4 4 4.0 7.0 11.0 14.0 18.0 20.0 30.0 40.0 60.0 85.0 110.0 150.0 200.0 220.0 240.0 260.0 280.0 300.0 10 10 9 8 8 8 7 7 6 6 6 6 6 6 5 5 5 5 3.5 6.0 9.0 12.0 15.0 19.0 25.0 33.0 50.0 75.0 100.0 130.0 180.0 190.0 210.0 230.0 250.0 260.0 11 11 10 9 9 9 9 9 7 7 7 7 7 7 7 7 7 7 3.0 5.5 8.0 10.0 14.0 17.0
41、22.0 30.0 45.0 68.0 90.0 110.0 160.0 170.0 190.0 210.0 230.0 240.0 12 12 12 10 10 10 10 9 8 8 8 8 8 8 8 8 8 8 25 40 50 85 140 170 250 450 650 1000 1300 1600 2600 3200 4200 5300 6400 84008 blankBS4G178-2:1986 BSI 07-1999 Publications referred to BS 89, Specification for direct acting indicating elect
42、rical measuring instruments and their accessories. BS G 231, Specification for conductors for general purpose aircraft electrical cables and aerospace applications. BS G 178, Crimped joints for aircraft electrical cables and wires. BS G 178-1, Specification for design requirements (including tests)
43、for components and tools. BS4G 178-2: 1986 BSI 389 Chiswick High Road London W4 4AL BSIBritishStandardsInstitution BSI is the independent national body responsible for preparing BritishStandards. It presents the UK view on standards in Europe and at the international level. It is incorporated by Roy
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