1、BRITISH STANDARD BS 5G 178-1:1993 Crimped joints for aircraft electrical cables and wires Part 1: Specification for design requirements (including tests) for components and toolsBS5G 178-1:1993 This British Standard, having been prepared under the direction of the Aerospace Standards Policy Committe
2、e, was published under the authority of the Standards Board and comes into effect on 15 February 1993 BSI 03-1999 The following BSI references relate to the work on this standard: Committee reference ACE/6 Draft for comment 92/73351 DC ISBN 0 580 21549 0 Committees responsible for this British Stand
3、ard The preparation of this British Standard was entrusted by the Aerospace Standards Policy Committee (ACE/-) to Technical Committee ACE/6, upon which the following bodies were represented: British Airways British Cable Makers Confederation British Rubber Manufacturers Association Civil Aviation Au
4、thority (Airworthiness Division) Electronic Components Industries Federation Ministry of Defence Society of British Aerospace Companies Ltd. Amendments issued since publication Amd. No. Date CommentsBS 5G 178-1:1993 BSI 03-1999 i Contents Page Committees responsible Inside front cover Foreword ii 1
5、Scope 1 2 Normative references 1 3 Definitions 1 4 Components 1 5 Tools 2 6 Completed joints 3 7 Test requirements 3 8 Type tests 5 9 Production control 6 Annex A (normative) Tests 7 Table 1 Pull-off loads, test currents and voltage drop values for copper and copper alloy conductor crimps (metric un
6、its) 4 Table 2 Pull-off loads, test currents and voltage drop values for aluminium and aluminium alloy conductor crimps (imperial units) 5 Table 3 Test sequence and number of specimens for tests 5 Table 4 Test sequence and number of specimens for additional tests on insulated or sealed joints 6 Tabl
7、e A.1 List of test fluids contained in BS 3G 100-2.3.12:1991 10 List of references Inside back coverBS5G 178-1:1993 ii BSI 03-1999 Foreword This British Standard, prepared under the direction of the Aerospace Standards Policy Committee, provides details of the requirements aircraft constructors and
8、operators for crimping connections for electrical cables for aircraft. The standard is published in separate Parts; Part1 relates to the design requirements and tests for the manufacture of terminal ends, connector contacts, cable splices and their associated crimping tools and Part2 relates to user
9、 control tests for crimped joints. This Part is a revision of BS4G178:1984 which is withdrawn. The principal changes introduced by this revision are a modification of the load/temperature cycling test, with emphasis on the stability of the crimped joint during the final stages of the test, and the a
10、ddition of a low air pressure test for sealed splices. Minor modifications and corrections to the text have been made and some performance data for size28 and30 conductors have been included in Table 1 at the request of industry. Reliable data for crimps on nickel plated conductors are not at presen
11、t available for inclusion in this revision. Testing of crimped joints to assess their suitability for aircraft shows that certain environmental conditions, e.g. vibration, have no significant effect on the performance the joints. It has, therefore, not been considered necessary to provide for such t
12、ests in the specification. 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 obligations. Summary of pag
13、es This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 10, 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 on theinside front cover.
14、BS5G 178-1:1993 BSI 03-1999 1 1 Scope This Part of BS5G178 specifies the design requirements and tests for components and tools for the crimping of insulated and non-insulated terminals and splices to general purpose electrical cables or equipment wires for aircraft with conductors of copper, copper
15、 alloy, aluminium or aluminium alloy, in locations in which the stabilized conductor temperature does not exceed the value specified for the relevant type of cable. Tests for the components, tools and crimped joints are described in Annex A. NOTEThe latest revision or new edition of an Aerospace Ser
16、ies standard is indicated by a prefix number. 2 Normative references This Part of BS5G178 incorporates, by reference, provisions from specific editions of other publications. These normative references are cited at the appropriate points in the text and the publications are listed on the inside back
17、 page. Subsequent amendments to, or revisions of, any of these publications apply to this Part of BS5G178 only when incorporated in it by updating or revision. 3 Definitions For the purposes of this Part of BS5G178 the following definitions apply. 3.1 crimping the physical compression or deformation
18、 of a conductor barrel or ferrule around a conductor in order to make a mechanical and electrical connection 3.2 crimped joint a permanent connection formed by crimping a terminal end, connector contact or cable splice onto electrical conductors 3.3 terminal end a device with barrel(s) accommodating
19、 electrical cable conductor(s) with or without additional provision to accommodate and support the conductor insulation, for connecting conductor(s) to equipment 3.4 connector contact a contact used in a fixed or free connector with a barrel at one end to accommodate an electrical cable conductor wi
20、th or without additional provision to support the conductor insulation 3.5 cable splice a device with barrel(s) accommodating electrical cable conductor(s) with or without additional provision to accommodate and support the conductor insulation for connecting conductors 3.6 insulation support that p
21、art of a terminal barrel or cable splice barrel which supports the conductor insulation 3.7 pre-insulated joint a crimped connection formed with an insulated terminal end or insulated cable splice 3.8 post-insulated joint an insulated crimped connection insulated after conductor crimping 3.9 crimpin
22、g tool a manually or power operated mechanical device for crimping and, where required, reforming the insulation support 3.10 positioner a locator turret or other device permanently or removably attached to a crimping tool serving correctly to locate and control the position of the crimp on the barr
23、el 3.11 flash material of the barrel or socket of a crimped joint extruded between the edge of the dies in a crimping tool during the crimping operation 3.12 cable and wire a single-core electric cable or wire or an individual core of a multi-core cable or wire 4 Components 4.1 Where installation co
24、nditions are suitable, terminal ends and cable splices shall conform to BSG204:1967, and connector contacts shall conform to BS9521:1983. Where installation conditions make it impossible to use terminal ends, cable splices or connector contacts conforming to these standards, any deviations shall be
25、declared in the declaration of design and performance (see4.5).BS5G 178-1:1993 2 BSI 03-1999 4.2 Terminal ends, connector contacts and splices shall be treated during manufacture to resist corrosion and/or to reduce contact resistance. The protective treatment and surface finish shall be of such a q
26、uality that the completed crimped joint conforms to the relevant requirements of clause 7. 4.3 The design of the terminal end, connector contact or splice shall be such that adequate engagement of the cable conductor in the completed joint can be readily established. 4.4 In the case of pre-insulated
27、 terminal ends and splices, during and after the crimping operation, the insulation and internal sleeve, if any, shall remain in its correct position. The insulation shall be colour coded in respect of its conductor size or sizes in accordance with the approved drawings 1) . 4.5 The manufacturers of
28、 the terminal ends, connector contacts or cable splices shall provide a standard form of declaration of design and performance as required by BS3G100-1:1973, covering each type, size and material of component. The declaration shall be based on tests made in accordance with this Part of BS5G178 by a
29、testing facility accepted by the approving authority, and shall include particulars of approved drawings, finish temperature range and known types, sizes and circular mil area (CMA) (see 8.1) of cable, crimping tools and dies, that may be used to make crimped joints conforming to the requirements of
30、 this standard. 4.6 The approving authority shall be provided with approved drawings in respect of terminal ends, connector contacts or cable splices, containing the limiting dimensions, material specifications, hardness, finish, jointing compounds (where used) and the sizes and types of cable for w
31、hich the components are suitable. Any changes in any of these features shall be notified to the approving authority, who may require a complete series of tests before accepting any further terminal ends, connector contacts or cable splices. 4.7 For all terminal ends or cable splices used on conducto
32、rs up to and including size12, the item shall include a barrel so designed that it will enclose and support the outside of the conductor insulation in such a way that it conforms to 7.6. NOTEFor post-insulated terminal ends or cable splices the insulation support feature of the installed product may
33、 be provided by the post-insulation so long as the requirements of 7.6 are met. 5 Tools 5.1 Where the insulation support barrel is deformed during the crimping operation, the action of the tool shall be such that both the conductor crimp and the insulation support are effected in one operation. 5.2
34、The crimped joint shall be formed by a tool so designed that it will: 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
35、 the effective diameter along the length of the crimped section by more than the amounts specified in the specification of the connector or contact manufacture; d) apply the appropriate mark, during the formation of the conductor crimp, when required by6.3, to indicate the die size or tool which has
36、 been used; e) not adversely affect the external protective treatment or insulation during the crimping operation; f) not fracture the terminal end, connector contact or cable splice, or produce excessive flash which would cause rough or sharp edges which can damage insulation. 5.3 Tools shall be ma
37、rked with the specification number where applicable and the manufacturers name, part number and serial number. 5.4 The approving authority shall be provided with approved drawings containing the following information: a) in respect of the associated crimping tools, the limiting dimensions, die refer
38、ences, and when applicable, the tool settings, locators, positioners or turrets, appropriate to the various combinations of conductors and components; b) the code of identification marks, so far as applicable (see6.3); c) the method of gauging. 1) For terminal ends, connector contacts or cable splic
39、es and tools used on military aircraft, the drawings have to be approved by the Ministry of Defence (Procurement Executive) Directorate of Standardization or through a design authority approved by the department as appropriate. Before granting approval the approving authority may require evidence th
40、at the terminal ends, connector contacts or cable splices conforming to the drawings will satisfy the test requirements of this standard. For civil aircraft, the Civil Aviation Authority (CAA), or design authority approved by the CAA may approve terminal ends, connector contacts or cable splices whi
41、ch conform to the requirements of this specification and such approvals have to include definition of the appropriate tools.BS5G 178-1:1993 BSI 03-1999 3 Any changes in any of these features shall be notified to the approving authority, who may require a complete series of tests before accepting any
42、 further terminal ends, connector contacts or cable splices. 6 Completed joints 6.1 The overall dimensions of the completed joints shall conform to BSG204:1967, BS9521:1983 or dimensions given by the design authority. 6.2 The mechanical strength and electrical performance of the completed joints sha
43、ll be such that they conform to clause 7 of this standard. 6.3 The completed joint shall, where practicable, be marked in accordance with the code declared in the approved drawings to identify the size of the crimping tool or die. Such markings shall be applied during the formation of the crimp. 7 T
44、est requirements 7.1 Inspection 7.1.1 When tested in accordance with A.3.1 the terminal ends, connector contacts, cable splices and tools shall conform to the approved drawings. 7.1.2 Dies or positioners used in forming the crimped joints shall conform to the approved drawings. 7.1.3 When visually i
45、nspected all crimped joints shall be as described in A.3.3 a) to f). 7.2 Voltage drop test When tested in accordance with A.4 the value of voltage drop across each joint shall not exceed the appropriate value given in Table 1 or Table 2. 7.3 Salt spray test When tested in accordance with A.5 the cri
46、mped joint shall show no evidence of flaking and blistering of plated surfaces and shall conform to 6.2. NOTE This test need not be performed on sealed splices and connector contacts that are subjected to the low pressure air test (see 7.11). 7.4 Load and temperature cycling test When tested in acco
47、rdance with A.6 the following shall apply. a) The initial value of voltage drop across each crimped joint, measured in accordance with A.4, shall not exceed the appropriate value given in Table 1 or Table 2. b) The difference between the initial voltage drop value measured at the installed test poin
48、ts (LTC voltage drop) and the initial crimped joint voltage drop value measured in accordance with A.4 shall be subtracted from each LTC voltage drop result during cycling to give the voltage drop for each crimped joint. During the last500 cycles the voltage drop per crimped joint shall not vary fro
49、m the value first obtained during this period by more than20%. c) The final value of voltage drop across each crimped joint shall not exceed150 % of the initial value of voltage drop across each crimped joint. 7.5 Tensile test When tested in accordance with A.7 the pull-off load shall not fall below the minimum value given in Table 1 or Table 2 as appropriate. 7.6 Insulation support test NOTEThis test is applicable only to those terminals and splices where the insulation support is designed to grip the conductor insulation. When tested in accordance with A.8 the cabl
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