1、SAE-AS56761ADOPTION NOTICESAE-AS56761, “SPLICING; CABLE TERMINAL, PROCESS FOR, AIRCRAFT“,was adopted on 29-OCT-99 for use by the Department of Defense(DoD). Proposed changes by DoD activities must be submitted tothe DoD Adopting Activity: Commander, Naval Air Warfare Center,Aircraft Division, Code 4
2、14100B120-3, Highway 547, Lakehurst, NJ08733-5100. Copies of this document may be purchased from theSociety of Automotive Engineers 400 Commonwealth DriveWarrendale, Pennsylvania, United States, 15096-0001. http:/www.sae.org/_Custodians: Adopting Activity:Navy - ASNavy - ASAir Force - 99FSC 5130DIST
3、RIBUTION STATEMENT A: Approved for public release; distributionis unlimited.SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirelyvoluntary, and its applicability and suitabilit
4、y for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.Copyright 19
5、99 Society of Automotive Engineers, Inc.All rights reserved. Printed in U.S.A.QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8510 FAX: (724) 776-0243TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX: (724) 776-0790SAE WEB ADDRESS: http:/www.sae.org400 Commonwealth Drive, Warrendale, PA 15096-0001AEROSPACE
6、 STANDARDAS56761Issued 1999-07Splicing; Cable Terminal, Process for, AircraftNOTICEThis document has been taken directly from U.S. Military Specification MIL-S-5676A, Amendment 1 and contains only minor editorial and format changes required to bring it into conformance with the publishing requiremen
7、ts of SAE technical standards. The initial release of this document is intended to replace MIL-S-5676A, Amendment 1. Any part numbers established by the original specification remain unchanged.The original Military Specification was adopted as an SAE standard under the provisions of the SAE Technica
8、l Standards Board (TSB) Rules and Regulations (TSB 001) pertaining to accelerated adoption of government specifications and standards. TSB rules provide for (a) the publication of portions of unrevised government specifications and standards without consensus voting at the SAE Committee level, and (
9、b) the use of the existing government specification or standard format.Under Department of Defense policies and procedures, any qualification requirements and associated qualified products lists are mandatory for DOD contracts. Any requirement relating to qualified products lists (QPLs) has not been
10、 adopted by SAE and is not part of this SAE technical document.SAE AS56761 - 2 -1. SCOPE AND CLASSIFICATION:1.1 This specification is designed to present detailed procedure to be followed in splicing cable terminals. The types of cable to which this specification applies are listed in Section 2 and
11、table I. 2. APPLICABLE SPECIFICATIONS AND DRAWINGS:2.1 The following specifications and drawings of the issue in effect on date of invitation for bids shall form a part of this specification to the extent specified herein:2.1.1 SpecificationsFederal: QQ-S-571 Solder; Soft (Tin, Tin-Lead, and Lead-Si
12、lver)V-T-276 Thread; CottonMilitaryMIL-C-1511 Cable; Steel (Carbon), Flexible PreformedMIL-C-5424 Cable; Steel (Corrosion-Resisting), Flexible Preformed (For Aeronautical Use)MIL-C-6708 Compound; Exterior-Surface, Hard-Film, Corrosive-PreventiveMIL-C-6940 Cable, Single Strand Non-Flexible Carbon Ste
13、el (Preformed)Air Force-Navy AeronauticalAN-W-22 Wire; Zinc Coated, Soft Steel2.1.2 Drawings:Air Force-Navy Aeronautical Standard DrawingAN100 Thimble - Wire Cable(Copies of this publication and copies of other publications referenced herein or required for Government procurement, and the Index of M
14、ilitary Aeronautical (AN or MIL) Standards, may be obtained upon application to the Commanding General, Air Materiel Command, Wright-Patterson Air Force Base, Dayton, Ohio; or the Commanding Officer, U.S. Naval Air Station, Johnsville, Pennsylvania.)SAE AS56761 - 3 -3. MATERIAL AND EQUIPMENT:3.1 Mat
15、erials:3.1.1 Thimbles: Thimbles shall conform to the requirements of Drawing AN100.3.1.2 Serving Cord: Serving cord shall conform to Specification V-T-276, type 111A, 12-ply.3.1.3 Preservative: The preservative shall conform to the requirements of Specification MIL-C-6708, type 1.3.1.4 Serving Wire:
16、 Serving or wrapping wire shall be in accordance with Specification AN-W-22.3.1.5 Solder: Solder shall conform to Specification QQ-S-571, class A.3.1.6 Flux: Solder flux shall be a compound of stearic acid (free from mineral acids) and rosin of the following proportions:Stearic acid 25 to 50%Rosin 5
17、0 to 75%3.2 Equipment:The following tools (see figure 14) are recommended for use in the preparation of cable terminal splices.3.2.1 Marlin Spike: This is a small pointed tool of oval cross-section with a screw driver handle.3.2.2 Side Cutting Pliers: The side cutting pliers are required for clippin
18、g off the strands after splicing.3.2.3 Splicing Clamp: A splicing clamp is useful for holding the cable in place in the thimble and in positioning the terminal during splicing operations.3.2.4 Mallet: A rawhide or hardwood mallet is needed for hammering the splice after finishing and before serving,
19、 in order to produce a neat looking splice.4. PREPARATION AND PROCEDURE:4.1 Cutting of Cable:4.1.1 Flexible Cable: The cable shall be cut to length by mechanical means only, such as a fine tooth hacksaw. The use of oxy-acetylene torches in any manner is not permitted.SAE AS56761 - 4 -4.1.2 Non-Flexi
20、ble Cable: Before cutting the cable the wires must be soldered or welded together to prevent slipping. The preferable process is to thoroughly tin and solder the cable for 2 to 3 inches by placing in a solder trough as shown in figure 15 and finishing smooth with a soldering tool. The cable may be c
21、ut diagonally to conform to the required taper finish shown in figure 16. The cable shall be cut to length by mechanical means, such as a fine tooth hacksaw, except as allowed in applicable subparagraphs under “Procedure.”4.2 Procedure:4.2.1 Operations for Flexible Cable: The procedure for the prepa
22、ration of terminal splices for flexible splices for flexible cable is described in the following paragraphs. The splice shall have five full tucks. For 1/16-inch 7 x 7 flexible steel cable, the procedure described herein for nonflexible cable may be used as an optional method.4.2.1.1 Forming of Term
23、inals: The cable shall be bent snugly around the proper size of thimble as specified in table I and clamped, the points of the thinble having previously been bent back at an angle of approximately 45 degrees to permit a close splice. If a regular splicing clamp is not available, the cable may be hel
24、d in place on the thimble by binding with cord, as shown in the accompanying illustrations. The length of the free end of the cable should be about 8 inches for sizes up to and including 5/32-inch 7 x 19 cable. For cable of larger sizes the length should be slightly greater. The standing wire should
25、 be clamped in a vise with the free end to the left of the standing wire and away from the operator.4.2.1.2 First Operation: Choose the free strand lying directly under the thimble points and separate it from the rest of the free ends by inserting the Marlin spike under it and spiralling the spike a
26、round the free end. The cable should then appear as in figure 1.4.2.1.3 Second Operation: Insert the Marlin spike under the first three strands of standing cable to the right of the thimble points. Insert the loose free strand under the three standing strands, tucking from left to right. (Figure 2 i
27、llustrates the condition of the cable at this point.)4.2.1.4 Third Operation: Choose the second free strand to the left of the thimble points and separate it from the others as before described. This wire should be the next to the left of the first free strand tucked. Insert the Marlin spike under t
28、he first two standing strands to the right of the thimble points and tuck the loose end under these two standing strands, tucking from left to right as in figure 3.4.2.1.5 Fourth Operation: Choose the third free strand to the left of the thimble points and separate as before. Insert the Marlin spike
29、 under one standing strand to the right of the thimble points and tuck the loose free end under this standing strand, tucking from left to right. The cable now appears as in figure 4.SAE AS56761 - 5 -4.2.1.6 Fifth Operation: Choose the center or core wire and separate it from the other free ends. It
30、 can be easily distinguished from the outside wires by its smooth even surface. The outside wires are waved evenly by being coiled around the center or core wire. Tuck the center free end under the last two standing strands used, and bring it out in the same opening as the second free end which was
31、tucked. The core wire should lie between the vise and the second free end as appears in figure 5.4.2.1.7 Sixth Opening: Choose the free strand which lies last to the left of the thimble points and separate as before. Insert the Marlin spike from right to left under the two standing strands immediate
32、ly to the left of the thimble points. Insert the loose free end from right to left under these two standing strands. This is the only place in the first round of tucks where the tuck is made from right to left. The cable should now appear as in figure 6. To complete the sixth operation, pull the fre
33、e end of the last strand tucked, until the loop shown in figure 6 disappears and there is no slack in the strand.4.2.1.8 Seventh Operation: Separate the two remaining free ends. Insert the Marlin spike under the first standing strand to the left of the thimble points. Choose the free end which lies
34、next in order of rotation to the first three wires tucked. This should be the fourth free strand to the left of the thimble points. Tuck this free strand under the lifted standing strand, tucking from left to right. Figure 7 illustrates the present condition of the splice.4.2.1.9 Eighth Operation: W
35、ith the Marlin spike, lift the second standing strand to the left of the thimble points. Tuck the remaining free strand under the lifted standing strand. Tuck from left to right. The cable should now appear as in figure 8.4.2.1.10 Ninth Operation: The finished condition of a splice depends considera
36、bly on the ninth operation, so it should be observed very closely. Choose the tucking strand which lies in the opening with the center strand. Grasp it firmly in a pair of fairly heavy pliers and pull sharply upon it several times away from the thimble. Then keeping the strand always taut, describe
37、a half circle with the pliers and pull steadily back into the throat of the thimble. (The throat of the thimble is the joint of the two ends lying between the four points, previously turned back at a 45 degree angle.) Continue this operation completely around the standing cable until each of the tuc
38、king strands has been pulled down away from the thimble and then back aginst the throat. Next pull down the free center strand, but do not pull it back.4.2.1.11 Tenth Operation: Choose the tucking strand to the right of the center free strand and tuck it over one standing strand and under the next s
39、tanding strand. Tuck from right to left. See figure 9. Continue this operation around the standing cable to the left until you have tucked all six of the tucking strands. Do not tuck the free center strand on this or any succeeding series of tucks. After tucking all six tucking strands repeat the ni
40、nth operation. This constitutes the second series of tucks and the cable should appear as in figure 10.4.2.1.12 Eleventh Operation: The third series of tucks is made exactly the same as the second series. (Followed by the ninth operation.)SAE AS56761 - 6 -4.2.1.13 Twelfth Operation: The six tucking
41、strands are now split in half, and a series of tucks are made in the same manner as that described for the full strands, but using only one-half of each strand. (Followed by the ninth operation.) See figure 11.4.2.1.14 Thirteenth Operation: The core wire or free center strand should now be cut off a
42、s close as possible to the standing cable. The six half strands which were tucked in the twelfth operation are again halved making them 1/4 the size of a full strand. A series of tucks is now made using six 1/4 strands. (Followed by the ninth operation.) See figure 12. This completes the tucking of
43、the strands.4.2.1.15 Pounding the Splice: Bend the thimble points back into position and tap them snugly against the splice. Using a hardwood anvil and a hardwood or rawhide faced mallet, start at the thimble points and drive the tucking strands from right to left just as they were tucked. Roll the
44、splice on the anvil while pounding in order that the strands may receive an even tautness. When the splice has been made taut and hard, cut off the tucking strands as close as practicable. Pound the taper slightly to lay the sheared ends.4.2.1.16 Serving the Splice: Start about 1/4-inch below the en
45、d of the taper and wrap smoothly up the taper until all of the sheared ends are covered. Then take five or six loose coils over thumb or finger and insert the end of the serving cord through the loose coils from the thimble and toward the taper. Now wrap the loose coils firmly over the inserted end
46、and pull up any slack by drawing the inserted end down toward the taper. Cut off close to the serving, and beat it lightly with the mallet to smooth it down. Two coats of shellac shall be applied to the serving to make it as nearly waterproof as possible. The finished splice should appear as in figu
47、re 13.4.2.2 Operations for Non-Flexible Cable: The procedure for the manufacture of terminal splices for non-flexible cable is described in the following paragraphs. This terminal must not be used on flexible cable, except that it may be used for 1/16-inch 7 x 7 flexible cable.4.2.2.1 Forming of Spl
48、ice: After soldering and cutting, the cable is securely bent around the proper size thimble and clamped, taking care that the cables lie close and flat, and that the taper end for finish lies on the outside. If it is necessary to trim the taper at this point in the process, it is preferable that it
49、be done by nipping, but grinding will be permitted provided a steel guard at least 3 inches long and 1/32 inch thick is placed between the taper end and the main cable during the operation, and that the heat generated from the grinding does not melt the solder and loosen the wires.4.2.2.2 Serving: Serving may be done by hand or machine, but in either case each serving convolution must touch the adjoining one and be pulled tightly against the cable, with spaces for permitting a free flow of solder and inspection, as shown in figure 16. Serving wire shall b
