1、 AEROSPACE STANDARD CRIMP TOOLS, TYPE 1, TERMINAL, HAND OR POWER ACTUATED, WIRE TERMINATION, PNEUMATIC TOOL FOR WIRE BARREL SIZES 0000 THROUGH 8 AS22520/23Copyright 2015 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted,
2、 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 AD
3、DRESS: http:/www.sae.org ISSUED2015-01REVISED2015-12THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8C2 REV.A FEDERAL SUPPLY CLASS 5120 AS22520/23 SHEET 1 OF 8 REV. A PROCUREMENT SPECIFICATION: AS22520 SAE Technical StandardsBoardRulesprovidethat:“ThisreportispublishedbySAE toadvancethestateoftechnicaland
4、engineering sciences. The use ofthisreport isentirelyvoluntary, andits applicability andsuitability for any particularuse, includingany patent infringementarising therefrom,is the soleresponsibility of theuser.”SAE reviewseachtechnical reportatleasteveryfiveyearsatwhichtimeitmayberevised,reaffirmed,
5、stabilized,orcancelled. SAEinvites yourwritten comments andsuggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS22520/23A RATIONALE REVISION REQUIRED TO CORRECT DIMENSIONS IN FIGURE 2 DETAIL B AND TABLE 1. NOTICE THE CO
6、MPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF AS22520. FIGURE 1 - M22520/23-01 BASIC TOOL AEROSPACE STANDARD AS22520/23 SHEET 2 OF 8 REV. A CRIMP TOOLS, TYPE 1, TERMINAL, HAND OR POWER ACTUATED, WIRE TERMINATION, PNEUMATIC TOOL
7、FOR WIRE BARREL SIZES 0000 THROUGH 8 FIGURE 2 - DIE CAP AND DIE ASSEMBLY AEROSPACE STANDARD AS22520/23 SHEET 3 OF 8 REV. A CRIMP TOOLS, TYPE 1, TERMINAL, HAND OR POWER ACTUATED, WIRE TERMINATION, PNEUMATIC TOOL FOR WIRE BARREL SIZES 0000 THROUGH 8 FIGURE 2 - DIE CAP AND DIE ASSEMBLY (CONTINUED) TABL
8、E 1 - INDENTER HOUSING AND INDENTER DIMENSIONS DIE ASSEMBLY PART NUMBER FOR CONTACT SIZE DETAIL A DETAIL B A DIA B C D E +.010/-.000 .002 .002 .002 .002 M225520/23-02 8 .500 .050 .170 .055 .055 M225520/23-03 6 .500 .060 .174 .060 .060 M225520/23-04 4 .650 .065 .187 .062 .062 M225520/23-05 0 .690 .09
9、4 .198 .070 .070 M225520/23-06 00 .850 .100 .210 .075 .075 M225520/23-07 0000 .875 .130 .250 .090 .090 M225520/23-08 1 .650 .091 .203 .047 .047 AEROSPACE STANDARD AS22520/23 SHEET 4 OF 8 REV. A CRIMP TOOLS, TYPE 1, TERMINAL, HAND OR POWER ACTUATED, WIRE TERMINATION, PNEUMATIC TOOL FOR WIRE BARREL SI
10、ZES 0000 THROUGH 8 FIGURE 3 - CONTACT LOCATORS TABLE 2 - LOCATOR DIMENSIONS LOCATOR PART NUMBER CONTACT SIZE (MATING END) A .005 B .005 “C“ .005 “D“ +.010 -.000 “E“ +.010 -.000 F .005 M22520/23-09 8 .170 .075 .495 .316 .266 -M22520/23-10 6 - - - .348 .316 .050 M22520/23-11 4 .170 .065 .495 .423 .343
11、 - M22520/23-12 4 - - - .423 .338 .050 M22520/23-13 1/0 .170 .025 .675 .618 .520 - M22520/23-14 1/0 - - - .615 .520 .050 M22520/23-15 2/0 - - - .694 .660 .050 M22520/23-16 4/0 - - - .787 .754 .050 REQUIREMENTS: THE COMPLETE REQUIREMENTS FOR PROCURING THE PRODUCT DESCRIBED HEREIN SHALL CONSIST OF THI
12、S DOCUMENT AND THE LATEST ISSUE OF AS22520. 1. CONFIGURATION: a. TOOL CONFIGURATION SHALL BE IN ACCORDANCE WITH FIGURES 1 TO 3, AND TABLES 1 AND 2. DIMENSIONS ARE IN INCHES. UNLESS OTHERWISE FIGURE 1 TOLERANCE IS .125 INCHES, AND FIGURES 2 AND 3 TOLERANCE IS .005 INCHES. b. BREAK ALL SHARP EDGES. c.
13、 AIR PRESSURE SOURCE REQUIREMENT SHALL BE 90 TO 120 LB/IN2(SEE APPLICATION NOTE). d. INDENTER CLOSURE SELECTOR POSITIVE DETENT AT EACH IS NOT REQUIRED. e. THE CENTERLINES OF OPPOSING INDENTERS MUST ALIGN WITHIN .020 INCH. f. INDENTER LENGTH IS CONTROLLED BY GAUGE CALLOUTS. g. CRIMP JOINT MAY BE OBTA
14、INED WITH AID OF A DIE ASSEMBLY. h. M22520/23-01 BASIC TOOL WEIGHT, LESS DIES AND LOCATORS, SHALL BE 19 POUNDS MAXIMUM. AEROSPACE STANDARD AS22520/23 SHEET 5 OF 8 REV. A CRIMP TOOLS, TYPE 1, TERMINAL, HAND OR POWER ACTUATED, WIRE TERMINATION, PNEUMATIC TOOL FOR WIRE BARREL SIZES 0000 THROUGH 8 i. TH
15、E FULL CYCLE MECHANISM SHALL BE TAMPER PROOF SO THAT IT CANNOT BE RELEASED DURING THE NORMAL CRIMPING CYCLE. WHEN THE CRIMPING IS COMPLETED, THE RETURN MECHANISM SHALL AID THE HANDLES AND DIES TO RETURN TO THEIR NORMALLY OPEN POSITION. THE REQUIREMENT SHALL APPLY REGARDLESS OF THE PLANE OR POSITION
16、OF THE TOOL, WITH OR WITHOUT A WIRED ASSEMBLY IN THE TOOL. j. THE FULL CYCLE MECHANISM SHALL BE A MECHANICAL OR PNEUMATIC MECHANISM WHICH ADVANCES THE INDENTERS TO CRIMP THE CONTACT. THE MECHANISM SHALL OPERATE IN SUCH A MANNER, THAT IT INSURES THE INDENTERS ARE COMPLETELY CLOSED FOR A PROPER CRIMP
17、ON THE CONTACT/CONDUCTOR COMBINATION. THE MECHANISM SHALL RELEASE AUTOMATICALLY AFTER THE CRIMP IS COMPLETED. 2. MATERIAL AND FINISH: MATERIAL SHALL BE IN ACCORDANCE WITH AS22520 EXCEPT AS FOLLOWS: a M22520/23-01 BASIC TOOL BODY SHALL BE ALUMINUM 356 WITH BLACK FINISH. b. DIE CAP AND BOOSTER END CAP
18、S SHALL BE ALUMINUM 6061 WITH ANODIZED FINISH OR TREATED TO RESIST CORROSION (COLOR OPTIONAL). c. BENCH MOUNT BRACKET SHALL BE COMMERCIAL GRADE STEEL WITH BLACK FINISH. d. INDENTER HOUSING SHALL BE 17-4 PH STAINLESS STEEL. e. INDENTERS SHALL BE TOOL STEEL, HEAT TREATED TO ROCKWELL C54-56. f. LOCATOR
19、S SHALL BE ALUMINUM 2024. 3. PART IDENTIFICATION NUMBER (PIN) AND MARKING: M22520 /23 -01 I I I I I I_ -01 BASIC TOOL, -02 THRU -08 DIE ASSEMBLIES, -09 THRU -16 LOCATORS (TABLE 3) I I_ DETAIL SPECIFICATION NUMBER I_ APPLICABLE CONTROLLING SPECIFICATION a. MARKING ON THE BASIC TOOL SHOWN IN FIGURE 1
20、SHALL INCLUDE THE M22520/23-01 PIN, SUPPLIER NAME OR SYMBOL AND PART NUMBER (LOCATION IS OPTIONAL). b. MARKING ON THE DIE ASSEMBLY CAP SHOWN IN FIGURE 2 SHALL INCLUDE THE DIE GAGE LIMITS SHOWN IN TABLE 3 AND APPLICABLE CONTACT SIZE SHOWN IN TABLE 1. c. MARKING ON THE LOCATOR FACE SHOWN IN FIGURE 3 S
21、HALL INCLUDE THE APPLICABLE PIN SHOWN IN TABLE 2 AND THE APPLICABLE CONTACT SIZE. 4. INSPECTION GAGES: INSPECTION GAGES SHALL BE IN ACCORDANCE WITH TABLE 3. TABLE 3 - DIE ASSEMBLY INSPECTION GAGE LIMITS DIE ASSEMBLY PART NUMBER CONTACT SIZE (WIRE BARREL) DIE GAGING LIMITS AS22520/3 GAGE PIN GO NO GO
22、M22520/23-02 8 .130 .136 M22520/3-18M22520/23-03 6 .171 .178 M22520/3-19 M22520/23-04 4 .195 .202 M22520/3-20M22520/23-05 0 .325 .332 M22520/3-21 M22520/23-06 00 .351 .358 M22520/3-22M22520/23-07 0000 .425 .432 M22520/3-23 M22520/23-08 1 .255 .265 M22520/3-24AEROSPACE STANDARD AS22520/23 SHEET 6 OF
23、8 REV. A CRIMP TOOLS, TYPE 1, TERMINAL, HAND OR POWER ACTUATED, WIRE TERMINATION, PNEUMATIC TOOL FOR WIRE BARREL SIZES 0000 THROUGH 8 5. ASSEMBLY AND APPLICATION INSTRUCTION IS REQUIRED FOR EACH BASIC TOOL. 6. PERFORMANCE REQUIREMENT: TOOL PERFORMANCE SHALL BE IN ACCORDANCE WITH AS22520 WITH THE FOL
24、LOWING EXCEPTIONS. a. INSPECTION GAGING: INSPECTION GAGING OF THE TOOL IS NOT APPLICABLE. INSPECTION GAGING OF EACH DIE ASSEMBLY IS REQUIRED. THE “GO” GAGE SHALL PASS FREELY THROUGH THE DIE SET. THE “NO-GO” GAGE MAY ENTER, BUT SHALL NOT PASS THROUGH THE DIE SET. PERFORM THE INSPECTION BY SELECTING T
25、HE APPROPRIATE AS22520/3 GAGE (OR EQUIVALENT PRECISION GAGE) FOR THE DIE SET FROM TABLE 3, ACTUATE THE TOOL TO THE FULLY CLOSED POSITION BY HOLDING THE TRIGGER BUTTON DOWN AND INSERT THE “GO” AND “NO-GO” GAGE BETWEEN THE INDENTERS. b. HUMIDITY (STEADY STATE) IS NOT REQUIRED. c. HANDLE, INDENTER AND
26、DIE RETURN OPERATION (FULL CYCLING) SHALL BE REQUIRED AFTER EACH CRIMP. THE AIR PRESSURE REQUIRED TO CRIMP A 4/0 CONTACT WITH PART NUMBER M39029/112 -4/0-2/0L WIRE BARREL BUSHING TO A 2/0 WIRE MAY REQUIRE 100 POUNDS PER SQUARE INCH. d. RATCHETING MECHANISM NOT REQUIRED. e. FULL CYCLING MECHANISM REQ
27、UIRED (REQUIREMENT AND TEST METHOD BELOW). REQUIREMENT: THE DIFFERENCE BETWEEN THE FIRST AND THIRD CRIMP MEASUREMENTS SHALL NOT EXCEED .010 INCH. TEST METHOD: WITH 90 LB/IN2. AIR SUPPLIED TO THE TOOL, CRIMP A .312 INCH DIAMETER SOFT COPPER ROD WITH A M22520/23-04 DIE ASSEMBLY. MEASURE AND RECORD THE
28、 ROD THICKNESS BETWEEN OPPOSING INDENTS. STARTING WITH A LOW AIR PRESSURE THAT WILL NOT ALLOW THE INDENTERS TO OPEN WHEN CRIMPED ON THE ROD, INCREASE THE AIR PRESSURE UNTIL THE TOOL COMPLETES THE CYCLE AND THE INDENTERS OPEN. AT THIS SAME AIR PRESSURE, CRIMP THE ROD A THIRD TIME. MEASURE AND RECORD
29、THE THICKNESS BETWEEN OPPOSING INDENTS. f. HIGH COMPRESSION FORCE NOT REQUIRED. g. COMPRESSION FORCE NOT REQUIRED. h. DEFORMATION AND AXIAL CONCENTRICITY: AFTER CRIMPING TO WIRE (WIRED CONTACTS), THE TOTAL INDICATOR READING (TIR) SHALL NOT EXCEED .030 INCHES FOR CONTACT SIZES 0000 THRU 8. i. VOLTAGE
30、 DROP SHALL BE IN ACCORDANCE WITH TABLE 4 AT THE SPECIFIED WIRE TEST CURRENT. VOLTAGE DROP SHALL BE TESTED IN ACCORDANCE WITH THE METHOD SPECIFIED IN AS22520. TEST LEADS SHALL BE PLACED 1/2 INCH FROM THE END OF THE CRIMP INDENTS, OR THE MINIMUM DISTANCE BEYOND 1/2 INCH. TABLE 4 - MAXIMUM VOLTAGE DRO
31、P FOR EACH CONTACT SIZE DIE ASSEMBLY PART NUMBER LOCATOR PART NUMBER CONTACT SIZE WIRE TEST CURRENT (AMPS) MAX VOLTAGE DROP (MILLIVOLTS) M22520/23-02 M22520/23-09 8 46 5.0 M22520/23-03 M22520/23-10 6 60 4.5 M22520/23-04 M22520/23-11 4 80 4.0 M22520/23-04 M22520/23-12 4 80 4.0 M22520/23-05 M22520/23-
32、13 1/0 125 3.0 M22520/23-05 M22520/23-14 1/0 125 3.0 M22520/23-06 M22520/23-15 2/0 185 8.0 M22520/23-07 M22520/23-16 4/0 225 6.0 M22520/23-08 M22520/23-14 1 125 3.5 j. TENSILE STRENGTH SHALL BE THE IN ACCORDANCE WITH AS22520 (TYPE I TOOL). k. LOW TEMPERATURE CRIMP NOT REQUIRED. l. SHOCK EXPOSURE NOT
33、 REQUIRED. AEROSPACE STANDARD AS22520/23 SHEET 7 OF 8 REV. A CRIMP TOOLS, TYPE 1, TERMINAL, HAND OR POWER ACTUATED, WIRE TERMINATION, PNEUMATIC TOOL FOR WIRE BARREL SIZES 0000 THROUGH 8 m. LIFE REQUIRED (REQUIREMENT AND TEST METHOD BELOW). REQUIREMENT: TENSILE STRENGTH SHALL BE IN ACCORDANCE WITH AS
34、22520 (TYPE 1 TOOL) ON THE LARGEST CONTACT SIZE BEING APPROVED FOR QUALIFICATION (SEE APPLICATION NOTES). THE TOOL SHALL REQUIRE NO ADJUSTMENTS OR REPAIRS DURING 1,000 CYCLES, BUT IT SHALL BE PERMISSIBLE TO REMOVE FOREIGN MATTER AND LUBRICATE THE TOOL EVERY 250 CYCLES. TEST METHOD: ONE M22520/23-01
35、TOOL WITH AN M22520/23-07 DIE ASSEMBLY AND M22520/23-16 LOCATOR SHALL BE TESTED FOR 1,000 CRIMPS ON COMMERCIAL LEADED BRONZE TEST RODS WITH A ROCKWELL B HARDNESS OF 850+2 WITH A DIAMETER .750 +.004, -.003 INCHES. THE ROD SHALL BE ADVANCED TO .500 INCHES AFTER EACH CRIMP. AFTER EVERY 250 CYCLES, THE
36、TOOL SHALL CRIMP SIX M39029/48-327, 328, OR -335 CONTACT ASSEMBLIES. THREE OF THE CONTACTS SHALL BE CRIMPED TO 4/0 SILVER OR TIN PLATED WIRE AND THREE TO 2/0 SILVER OR TIN PLATED WIRE USING THE PART NUMBER M39029/112 -4/0-2/0L WIRE BARREL BUSHING. EXAMINE THE TOOL FOR FOREIGN MATTER AND VERIFY LUBRI
37、CATION (SEE ASSEMBLY INSTRUCTIONS). PERFORM TENSILE STRENGTH ON ALL CONTACTS. IF A SMALLER CONTACT SIZE IS BEING TESTED, THE SMALLEST WIRE AND LARGEST WIRE SIZE SPECIFIED FOR THE CONTACT SHALL BE TESTED. n. SALT SPRAY NOT REQUIRED. 7. QUALIFICATION REQUIREMENT: QUALIFICATION TESTS: FOR THE REQUIRED
38、AS22520 TYPE 1 SEQUENCE TESTING THE FULL CYCLE MECHANISM TEST SHALL BE PERFORMED IN PLACE OF THE RATCHETING MECHANISM TEST. QUALIFICATION TOOL SAMPLES: THE QUALIFICATION SAMPLE SHALL CONSIST OF TWO M22520/23-01 BASIC TOOLS TO BE USED WITH ALL DIE ASSEMBLIES AND LOCATORS FOR WHICH QUALIFICATION IS DE
39、SIRED. FOR LIFE CYCLE ONLY A 4/0 WIRE OR 2/0 WIRE WITH CONTACT BUSHING SHALL BE TESTED. QUALIFICATION CRIMP SPECIMENS: UNLESS OTHERWISE SPECIFIED, FOUR CRIMP ASSEMBLIES SHALL BE TESTED FOR EACH DIE ASSEMBLY AND LOCATOR. QUALIFICATION INDENTER AND DIE RETURN OPERATION (FULL CYCLING) CRIMP SPECIMENS:
40、SIX WIRED ASSEMBLIES FOR EACH CONTACT SIZE AND WIRE PLATING ACCOMMODATED BY THE TOOL AND DIES UNDER TEST SHALL BE PREPARED. THREE ASSEMBLES SHALL BE WITH THE LARGEST SIZE WIRE ACCOMMODATED BY THE CONTACT AS SPECIFIED IN TABLE 5 AND THREE WITH THE SMALLEST WIRE WITH THE APPROPRIATE CONTACT BUSHING AS
41、 APPLICABLE. 8. QUALITY CONFORMANCE REQUIREMENTS: GROUP A INSPECTION: THE QUALITY CONFORMANCE INSPECTION OF GROUP A SHALL BE PERFORMED AS LISTED IN AS22520, WITH THE FOLLOWING EXCEPTIONS. a. HANDLE, INDENTER, AND DIE RETURN OPERATION (FULL CYCLING) REQUIRED AS SPECIFIED HEREIN. b. RATCHETING MECHANI
42、SM NOT REQUIRED. c. HIGH COMPRESSION FORCE NOT REQUIRED. 9. APPLICATION NOTES: a. AS22520/23 TOOLS CRIMP THE CONTACTS SHOWN IN TABLE 5. AEROSPACE STANDARD AS22520/23 SHEET 8 OF 8 REV. A CRIMP TOOLS, TYPE 1, TERMINAL, HAND OR POWER ACTUATED, WIRE TERMINATION, PNEUMATIC TOOL FOR WIRE BARREL SIZES 0000
43、 THROUGH 8 TABLE 5 - AS22520/23 APPLICABLE CONTACTS 1/ CONTACT PART NUMBER M39029 CONTACT SIZE (WIRE BARREL) CONTACT SIZE (MATING END) DIE ASSEMBLY PART NUMBER M22520/23- LOCATOR PART NUMBER M22520/23- /29-214 8 8 02 09 /30-220 8 /44-291 /45-298 8 /48-317 6 6 03 10 /48-318 6N /48-319 6G /49-329 6 /4
44、9-330 6G /29-215 4 4 04 11 /30-221 4 /44-292 /45-299 4 /48-320 4 4 04 12 /48-321 4N /48-322 4G /49-331 4 /49-332 4G /48-323 1 1/0 08 14 /48-324 1/0N /49-333 1/0 /29-216 1/0 1/ 05 13 /30-222 1/0 /44-293 1/ /45-300 0 /48-325 2/0 2/ 06 15 /48-326 2/0N /49-334 2/0 /48-327 4/0 4/ 07 16 /48-328 4/0N /49-3
45、35 4/0 1/ SEE AS39029 FOR OBSOLETE CONTACTS. 2/ THE SAME WIRE SIZE AND THE WIRE BARREL CONTACT SIZE CAN BE CRIMPED WITH DIE ASSEMBLY AND LOCATOR AS SHOWN. FOR SMALLER WIRE SIZES AN AS39029/112 SLEEVE IS REQUIRED EXCEPT FOR WIRE SIZE 1 WHICH CAN BE CRIMPED IN 1/0 WIRE BARREL CONTACT SIZE WITH THE DIE
46、 AND LOCATOR SHOWN (SEE AS39029). b. AS22520/23 SUPERSEDES MIL-DTL-22520/23. PART NUMBERS REMAIN UNCHANGED. c. THE MAXIMUM VOLTAGE DROP FOR NICKEL PLATED WIRE MAY BE SLIGHTLY GREATER THAN THE SILVER AND TIN PLATED WIRE VALUES SHOWN IN TABLE 4. d. AS22520/23 IS DESIGNED TO WITHSTAND AIR PRESSURE LESS
47、 THAN 150 POUNDS. PRESSURE ABOVE 150 POUNDS MAY DAMAGE THE TOOL. 10. SPECIFICATION NOTE: REVISION INDICATOR: A CHANGE BAR (l) LOCATED IN THE LEFT MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WHERE TECHNICAL REVISIONS, NOT EDITORIAL CHANGES, HAVE BEEN MADE TO THE PREVIOUS ISSUE OF THIS DOCUMENT. AN (R) SYMBOL TO THE LEFT OF THE DOCUMENT TITLE INDICATES A COMPLETE REVISION OF THE DOCUMENT, INCLUDING TECHNICAL REVISIONS. CHANGE BARS AND (R) ARE NOT USED IN ORIGINAL PUBLICATIONS NOR IN DOCUMENTS THAT CONTAIN EDITORIAL CHANGES ONLY.
