1、_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 entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, 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 2011 SAE International All rights reserved. No part of this publication ma
3、y be reproduced, stored in a retrieval system or transmitted, 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 US
4、A) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS7928BAEROSPACESTANDARDAS7928 REV. B Issued 1999-06 Revised 2011-03Superseding AS7928A Termina
5、ls, Lug: Splices, Conductor: Crimp Style,Copper, General Specification For FSC 5940 RATIONALETo Incorporate AS7928A-A1 1. SCOPE 1.1 Scope This specification covers insulated and uninsulated crimp-style copper terminal lugs and conductor splices for stranded conductors.1.2 Classification Terminals an
6、d conductor splices covered by this specification shall be of the following types and classes, as specified (see 6.3): Type I - Uninsulated Type II - Insulated Class 1 - Terminals and conductor splices which conform to all of the requirements of this specification when installed with the crimping to
7、ol or crimping dies shown on the applicable AS, specification sheet. Class 2 - Terminals and conductor splices which conform to the material and marking requirements of this specification are replaceable by class 1 terminals, and conform to the performance requirements of this specification when cri
8、mped with a tool having crimping dies and motion conforming to the terminal manufacturers control drawing required by 3.6 (see 6.1.5). SAE AS7928B Page 2 of 322. APPLICABLE DOCUMENTS 2.1 Issues of Documents The following publications form a part of this document to the extent specified herein. The l
9、atest issue of SAE publications shall apply. The applicable issue of the other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in t
10、his document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sa
11、e.org.AMS1424 Deicing/Anti-Icing Fluid, Aircraft, SAE Type I AS7928/1 Terminals, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Crimp Style, Copper, Insulated, Ring Tongue, for Thin Wall Wire, Type II Class 1 for 105 C Total Conductor TemperatureAS7928/2 Terminals, Lug and Splices, C
12、onductor, Crimp Style, Copper, Insulated, Rectangular Tongue, for Thin Wall Wire, Type II, Class 1 for 105 C Total Conductor Temperature AS7928/4 Terminals, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Insulated, Ring Tongue, Bell-Mouthed, Type II, Class 1 (for 150 C) Total Conduct
13、or Temperature) AS7928/5 Terminals, Lug and Splices, Conductor, Crimp Style, Splice, Electric (Permanent, Type II, Class 1) for 105 C Total Conductor Temperature AS7928/6 Terminals, Lug and Splices, Conductor, Crimp Style, Splice, Electric (Permanent, Type II, Class 1) for 150 C Total Conductor Temp
14、erature AS7928/7 Terminal Lug and Splices, Conductor, Crimp Style, Copper, Terminal Lug, Crimp Style, Copper, Uninsulated, Ring Tongue Type I, Class 1 for 175 C Total Conductor Temperature AS17143 Terminal, Lug, Crimp Style, Copper, Insulated, Rectangular Tongue, Type II, Class 1 for 105 C Total Con
15、ductor Temperature AS20659 Terminal, Lug, Crimp Style, Copper, Uninsulated, Ring Tongue, Type I, Class 1, for 175 C Total Conductor Temperature AS21004 Terminal, Lug, Uninsulated, Rectangular Tongue, Crimp Style, Copper, Type I, Class 1 for 175 C Total Conductor Temperature AS25036 Terminal, Lug, Cr
16、imp Style, Copper, Insulated, Ring Tongue, Bell-Mouthed, Type II, Class 1(for 105 C Total Conductor Temperature) AS25189 Terminal, Lug, Flag Type, Crimp Style, Copper, Class I AS25274 Cap, Electrical (Wire End, Crimp Style, Type II, Class 1) for 105 C Total Conductor Temperature SAE AS7928B Page 3 o
17、f 322.1.2 U.S. Government Publications Available from the Document Automation and Production Service (DAPS), Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-9495, https:/assist.daps.dla.mil/quicksearch/.FEDERALTT-I-735A Isopropyl Alcohol PPP-B-585 Boxes, Wood, Wire bound P
18、PP-B-676 Boxes, Setup MILITARYMIL-STD-129 Standard Practice for Military Marking MIL-STD-202 Test Methods for Electronic and Electrical Component Parts MIL-HDBK-454 General Guidelines for Electronic Equipment MIL-STD-1916 DOD Preferred Methods for Acceptance of Products MIL-STD-2073-1 DOD Standard P
19、ractice for Military Packaging MIL-PRF-5606 Hydraulic Fluid, Petroleum Base, Aircraft, Missile, and Ordnance MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-PRF-7808 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base MIL-DTL-83133 Turbine Fuels, Aviation, Kerosene Types, NATO F-3
20、4 (JP-8), NATO F-34, and JP-8+100 2.2 Other Publications 2.2.1 ANSI Publications Available from American National Standards Institute, 25 West 43rdStreet, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org.ANSI/ISO 10012-1 Quality Assurance Requirements for Measuring Equipment 2.2.2 ASQ Public
21、ations Available from American Society for Quality, 600 North Plankton Avenue, Milwaukee, WI 53203, Tel: 800-248-1946 (United States or Canada) or +1-414-272-8575 (International), www.asq.org. ASQ Z1.4 Sampling Procedures and Tables for Inspection by Attributes SAE AS7928B Page 4 of 322.2.3 ASTM Pub
22、lications Available from ASTM International, 100 Barr harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.orgASTM B 75 Seamless Copper Tube ASTM B 152 Copper Sheet, Strip, Plate and Rolled Bar ASTM B 187 Standard Specification for Copper, Bus Bar, Rod, and Shap
23、es and General Purpose Rod ASTM B 272 Copper Flat Products with Finished (Rolled or Drawn) Edges (Flat Wire and Strip) ASTM B 339 Standard Specification for Pig Tin ASTM B 545 Standard Specification for Electrodeposited Coatings of Tin ASTM D 1974 Methods for Closing, Sealing and Reinforcing Fiberbo
24、ard Boxes ASTM D 5118/ Fabrication of Fiberboard Shipping Boxes ASTM D 5118M ASTM D 3951 Package, Commercial ASTM D 3953 Steel and Seals, Flat, Strapping ASTM D 5486 Standard Specification for Pressure-sensitive Tape for Package, Box Closure, and Sealing ASTM D 6251 Standard Specification for Natura
25、l Wood-Cleated Panelboard Shipping Boxes 2.2.4 ISO Publications Available from American National Standards Institute, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org or the International Organization for Standardization, 1, rue de Varemb, Case postale 56, CH-1211 Geneva
26、 20, Switzerland, Tel: +41-22-749-01-11, www.iso.org.ISO 10012-1 Quality Assurance Requirements for Measuring Equipment 2.2.5 NCSL Publications Available from Natioanl Conference of Standards Laboratories, 2995 Wilderness Place, Suite 107, Boulder, CO 80301-5404, Tel: 303-440-3339, www.ncsli.org.NCS
27、L Z540-1 General Requirements for Calibration Laboratories and Measuring and Test Equipment 2.2.6 NIST Publications Available from National Institute of Standards and Technology, 100 Bureau Drive, Stop 1070, Gaithersburg, MD 20899-1070, Tel: 301-975-6478, www.nist.gov.FED-STD-H28 Screw-Threads Stand
28、ards for Federal Services SAE AS7928B Page 5 of 323. REQUIREMENTS 3.1 Acquisition Specifications The individual item requirements shall be as specified this acquisition specification and in accordance with the applicable detail specification (see 2.2). If there are any conflict between requirements
29、of this specification and the detail specification, the latter shall govern. Unless otherwise specified by contract or purchase order, product purchased to this specification will be supplied to the latest revision in effect at issuance of the contract or purchase order (see 6.2). 3.2 Qualification
30、The lug terminals and conductor splices furnished under this specification shall be products which are qualified for listing on the applicable qualified products list at the time set for opening of bids or purchase (see 4.5 and 6.3). 3.3 Material The material shall be as specified herein. However, w
31、hen a material not specified is used, it shall be such that the lug terminals and conductor splices conform to the performance requirements of this specification. Some materials have application restrictions (see 6.1.10). Acceptance or approval of any constituent material shall not be construed as a
32、 guaranty of the acceptance of the finished product. Alternate materials shall be approved by the activity responsible for qualification (see 6.3). 3.3.1 Metals The lug terminals and conductor splices shall be fabricated from copper conforming to ASTM B 187, ASTM B 272, ASTM B 152, and ASTM B 75 or
33、as specified on the applicable AS specification sheet. 3.3.2 Insulation Material The insulation material shall be permanently colored thermoplastic or as specified on the applicable AS or MS specification sheet. Conductor splices need not be totally colored, but a permanent identifying color shall b
34、e clearly distinguishable on some portion of the splice. The insulation material shall be non-corrosive, resistant to abrasion and fungus, and shall not support combustion. 3.3.3 Fungus-Resistant Material Only fungus-resistant material shall be used. The manufacturer shall submit certification to th
35、is effect for qualification approval. The certification shall be included in the manufacturers certified test report to the activity responsible for qualification (see 4.5.2.1) 3.4 Design and Construction Lug terminals and conductor splices shall conform in all respects to the design, dimensions and
36、 construction specified herein and on the applicable AS or MS specification sheet. Each terminal size shall be designed for attachment to wire sizes specified on the applicable AS or MS specification sheet by having the terminal receiving barrel reshaped around the conductor. For class 1 terminals a
37、nd conductor splices, it shall be possible to perform the reshaping operation by means of a crimping tool or crimping dies conforming to the applicable AS or MS specification sheet. For class 2 terminals and conductor splices, it shall be possible to perform this reshaping operation by means of tool
38、ing detailed on the manufacturers control drawings. Terminals and conductor splices shall exhibit no evidence of fracturing or spalling as a result of the reshaping operation. Wire insertion shall be facilitated by bell mouth or chamfer of wire barrel. There shall be no protruding sharp edges of the
39、 terminal or conductor splice when reshaping the crimp barrel to the contour of the wire during or after the crimping operation. SAE AS7928B Page 6 of 323.4.1 Wire Facility Each size lug terminal and conductor splice shall be designed for attachment to the wire diameter range or size specified in th
40、e applicable AS or MS specification sheet. 3.4.2 Mounting Holes The tongue of each size lug terminal shall be designed for attachment to the stud size specified. The diameter of the clearance hole for each stud size is listed in Table 1 or on the applicable AS or MS specification sheet. TABLE 1 - CL
41、EARANCE HOLE (REFERENCE) Stud Size 1/Clearance Hole Diameter Clearance Hole (Reference) Minimum Maximum Inch mm Inch mm Inch mm 2 (0.086) 0.090 0.098 0.086 2.18 0.190 4.83 0.437 11.10 4 (0.112) 0.114 0.122 0.090 2.29 0.193 4.90 0.448 11.38 5 (0.125) 0.129 0.137 0.098 2.49 0.203 5.16 0.463 11.76 6 (0
42、.138) 0.142 0.152 0.112 2.84 0.216 5.49 0.500 12.70 8 (0.164) 0.168 0.178 0.114 2.90 0.220 5.59 0.510 12.95 10 (0.190) 0.193 0.203 0.122 3.10 0.236 5.99 0.525 13.34 12 (0.216) 0.220 0.236 0.125 3.18 0.250 6.35 0.625 15.88 1/4 (0.250) 0.260 0.275 0.129 3.28 0.260 6.60 0.651 16.54 5/16 (0.312) 0.323 0
43、.338 0.137 3.48 0.275 6.99 0.666 16.92 3/8 (0.375) 0.385 0.400 0.138 3.51 0.312 7.92 0.750 19.05 7/16 (0.437) 0.448 0.463 0.142 3.61 0.323 8.20 0.770 19.56 1/2 (0.500) 0.510 0.525 0.152 3.86 0.338 8.59 0.785 19.94 5/8 (0.625) 0.651 0.666 0.164 4.17 0.375 9.53 0.875 22.23 3/4 (0.750) 0.770 0.785 0.16
44、8 4.27 0.385 9.78 0.895 22.73 7/8 (0.875) 0.895 0.910 0.178 4.52 0.400 10.16 0.910 23.11 1/ Stud size in accordance with FED-STD-H28. Metric equivalents (to the nearest 0.01 mm) are given for general information only andare based upon 1 inch - 25.4 mm. 3.4.3 Wire Insulation Support When specified on
45、 the applicable AS or MS specification sheet, wire insulation supports shall be required which encompasses the wire insulation and which when deformed by the crimping tool is not required to grip the wire insulation. 3.4.4 Insulation Insulation of polyvinylchloride (PVC) shall not be allowed for use
46、 in or on any aerospace vehicles (see individual specification sheet). Insulated (type II) lug terminals and conductor splices shall be insulated over the entire outer surfaceof the barrel and wire insulation support. The insulation, and metal sleeve if used, shall remain in its original position on
47、 the barrel of the terminal or conductor splice before and after crimping except as specified in 3.5.5. The insulation shall exhibit no evidence of fracturing or spalling as a result of the reshaping operation. SAE AS7928B Page 7 of 323.4.5 Finish Unless otherwise specified (see 3.1), lug terminals
48、and conductor splices shall have conducting parts tin plated over their entire surface in accordance with ASTM B 545 and ASTM B 339 (see 6.1.11). Bare copper exposed at slug-out points on lug terminals, in strip form, shall not in itself be cause for rejection. The slug-out points shall not exceed 1
49、/8 inch in width.Mercury shall not be used in the manufacture of these terminals. 3.5 Performance Requirements The lug terminals and conductor splices shall conform to the following requirements, when crimped to each of the specified wire sizes with the applicable tool or crimping dies specified in 3.4. The specified performance of the terminals and splices is premised on there being no nicked or broken strands of the conductor.
