1、 AEROSPACE STANDARD SPLICE, IN-LINE, ELECTRIC, CRIMP, NI/CU, ENVIRONMENTAL, HEAT-SHRINKABLE SLEEVE (175 C), 3 X 3 SEALANT OPENING AS81824/10Copyright 2012 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or
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3、w.sae.org ISSUED 2012-07THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8C2 FEDERAL SUPPLY CLASS 5940 AS81824/10SHEET 1 OF 4 PROCUREMENT SPECIFICATION: AS81824SAE Technical Standards Board Rules provide that: “This report ispublished by SAE toadvance thestate of technicalandengineering sciences. Theuse of
4、thisreport is entirelyvoluntary, andits applicability and suitability forany particularuse,including any patent infringement arising therefrom, isthe soleresponsibilityofthe user.”SAE reviews eachtechnicalreport at least every five years at which time itmay berevised,reaffirmed, stabilized, orcancel
5、led. SAE invites yourwrittencomments andsuggestionsSAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/AS81824/10 RATIONALE THIS DOCUMENT PROVIDES THE REQUIREMENTS FOR A NEW ENVIRONMENT RESISTANT SPLICE FOR USE WITH MULTIPLE CONDUCTO
6、R SPLICING. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING SPLICE DESCRIBED HEREIN SHALL CONSIST OF THIS DOCUMENT AND THE LATEST ISSUE OF: SAE AS81824. TABLE 1 - CONSTRUCTION DETAILS PART NUMBER WIRE RANGE A B C D E MAX COLOR CODE WEIGHT LB (KG) PER 1000 PCS MAX REF M81824/10-1 SEE TABLE 4 .053 (1.3
7、5) .045 (1.14) .080 (2.03) .075 (1.91) .510 (12.95) .490 (12.45) .245 (6.22) .225 (5.72) .015 (0.38) RED 5.40 (2.5) M81824/10-2 SEE TABLE 4 .070 (1.78) .063 (1.60) .107 (2.72) .100 (2.54) .585 (14.86) .565 (14.35) .280 (7.11) .260 (6.60) .020 (0.51) BLUE 6.00 (2.7) M81824/10-3 SEE TABLE 4 .103 (2.62
8、) .095 (2.41) .155 (3.94) .146 (3.71) .585 (14.86) .565 (14.35) .280 (7.11) .260 (6.60) .050 (1.27) YELLOW 7.25 (3.9) *I.D. “AS RECEIVED” DIMENSIONS ARE IN INCHES METRIC EQUIVALENTS (TO THE NEAREST 0.01 MM) ARE GIVEN FOR GENERAL INFORMATION ONLY AND ARE BASED UPON 1 INCH = 25.4 MM UNLESS OTHERWISE S
9、PECIFIED, TOLERANCES ARE .005 (0.13 MM) FOR THREE PLACE DECIMALS .01 (0.25 MM) FOR TWO PLACE DECIMALS SEALING SLEEVE B C D TYPICAL .110 .080 AINSPECTION WINDOW WIRE STOP STRIPE COLOR CODES IN ACCCORDNACE WITH TABLE METAL CRIMP SPLICE E 1.300 0.075 0.087 MIN 0.200 MIN *0.093 MIN 0.093 MIN0.285 MAX0.1
10、00 NOM THICKNESS SEALING RING 1 (2 PL) AEROSPACE STANDARD AS81824/10SHEET 2 OF 4 SPLICE, IN-LINE, ELECTRIC, CRIMP, NI/CU, ENVIRONMENTAL, HEAT-SHRINKABLE SLEEVE (175 C), 3 X 3 SEALANT OPENING REQUIREMENTS: MATERIAL: METAL CRIMP SPLICE: COPPER PER ASTM B280, ASTM B75-68, ASTM B1, ASTM B187 OR ASTM B15
11、2 INSULATION SLEEVE: HEAT SHRINKABLE, TRANSPARENT POLYVINYLIDENE FLUORIDE PER THE PERFORMANCE REQUIREMENTS OF SAE AS23053/8. SEALING MATERIAL: MODIFIED THERMOPLASTIC, SEE PROCUREMENT SPECIFICATION. FINISH: METAL NICKEL PLATED PER SAE AMS-QQ-N-290. 1. CONTOUR: CONTOUR MAY VARY FROM THAT SHOWN. 2. AVE
12、RAGES OF DIAMETERS “A” AND “B” OF THE INSPECTION SAMPLES MUST BE WITHIN SPECIFIED LIMITS. 3. “B” DIAMETER SHALL NOT INCLUDE COLOR STRIPE. 4. NO ETCHING OR SOLVENT TREATING OF THE ASSOCIATED WIRE INSULATION SHALL BE PERMITTED. 5. RESERVED 6. RESERVED 7. RESERVED 8. QUALIFICATION: QUALIFICATION SHALL
13、BE TESTED IN ACCORDANCE WITH SAE AS81824. SEE 8.3 FOR EXCEPTIONS. 8.1 TERMINATION TOOL: FOR QUALIFICATION TESTING, ONLY SPLICE ASSEMBLIES MADE WITH WIRE CONFORMING TO M22759/12 SHALL BE TESTED WITH THE METAL SPLICE. THE SEALING AND INSULATING SLEEVE SHALL BE INSTALLED WITH THE APPLICABLE HEATING TOO
14、L. FOR CRIMPING TOOLS, SEE TABLE 2. TABLE 2 - CRIMP TOOLS SPLICE PART NO. BASIC CRIMP TOOL NO. DIE NO. M81824/10-1 M81824/10-2 M22520/5-01 M22520/10-01 M22520/37-01 M22520/5-103 M22520/10-104 N/A M81824/10-3 M22520/5-01 M22520/10-01 M22520/37-01 M22520/5-102 M22520/10-103 N/A 8.2 WIRE RANGE: TABLE 3
15、 LISTS TYPICAL WIRE RANGES FOR EACH SPLICE SIZES. FOR MULTIPLE CONDUCTOR SPLICING, DETERMINE THE PROPER CRIMP BARREL SIZE BASED ON TOTAL CONDUCTOR MIL AREA (CMA) OR CONDUCTOR AREA IN MM2FOR EACH SIDE TABLE 3 - QUALIFICATION SPLICE CONFIGURATION PART NUMBER MULTIPLE WIRE SIZE (QTY) ON THREE SEALANT O
16、PENING BOTH SIDES MIN SAMPLE COMBINATION /1 MAX SAMPLE COMBINATION M81824/10-1 26(2) 26(3) + 24(1) M81824/10-2 26(1) + 22(1) 26(1) + 24(5) M81824/10-3 24(1) + 18(1) 24(3) + 22(3) /1 ONE SEALANT OPENING IS EMPTY IN THE MINIMUM COMBINATION CONFIGURATION. 8.3 FOLLOWING EXCEPTIONS OR VARIATIONS TO SAE A
17、S81824 QUALIFICATIONS APPLY FOR MULTIPLE WIRE TERMINATION TESTING: 8.3.1 VOLTAGE DROP (REFERENCE: SAE AS81824 PARAGRAPH 4.8.1): REFERENCE VOLTAGE DROP SHALL BE DETERMINED BY AVERAGING 4 SAMPLES OF APPLICABLE COMBINATION WIRES WITH SOLDERED CRIMP SPLICES. THE REFERENCE MILLIVOLT SHALL BE MADE BY PUNC
18、TURING THE LARGEST WIRE INSULATION ON BOTH SIDES OF THE CRIMP 1/16 INCH BACK FROM THE ENDS OF THE SEALING SLEEVE. AEROSPACE STANDARD AS81824/10SHEET 3 OF 4 SPLICE, IN-LINE, ELECTRIC, CRIMP, NI/CU, ENVIRONMENTAL, HEAT-SHRINKABLE SLEEVE (175 C), 3 X 3 SEALANT OPENING 8.3.2 TENSILE STRENGTH (REFERENCE:
19、 SAE AS81824 PARAGRAPH 4.8.5): THE TENSILE STRENGTH SHALL BE TESTED AS FOLLOWS: 8.3.2.1 SMALLEST WIRE ON EACH SIDE SHALL BE ATTACHED TO OPPOSING GRIPS OF THE PULL TESTER WITH THE SPLICE UNATTACHED IN THE APPROXIMATE CENTER, AND PULLED WITH SUFFICIENT FORCE* TO PULL ONE OF THE WIRES OUT OF THE SPLICE
20、 OR BREAK ONE OF THE WIRES, OR BREAK THE SPLICE. 8.3.2.1.1 THE PASS/FAIL CRITERIA FOR THIS TEST IS THE AS81824 ESTABLISHED MINIMUM STRENGTH FOR THE WIRE TYPE (PLATING) AND GAGE SIZE OF THE WIRE THAT PULLED OUT OR BROKE. IF THE SPLICE BROKE, THE TENSILE VALUE FOR THE SMALLEST WIRE ATTACHED TO THE PUL
21、L TESTER GRIPS WILL APPLY. 8.3.2.2 ON A DIFFERENT BATCH OF SAMPLES THE LARGEST WIRE IN EACH OF THE SPLICE SHALL BE ATTACHED TO OPPOSING GRIPS OF THE PULL TESTER WITH THE SPLICE UNATTACHED IN THE APPROXIMATE CENTER, AND PULLED WITH SUFFICIENT FORCE* TO PULL ONE OF THE WIRES OUT OF THE SPLICE OR BREAK
22、 ONE OF THE WIRES OR BREAK THE SPLICE. 8.3.2.2.1 THE PASS/FAIL CRITERIA FOR THIS TEST IS THE AS81824 ESTABLISHED MINIMUM STRENGTH FOR THE WIRE TYPE (PLATING) AND GAGE SIZE OF THE WIRE THAT PULLED OUT OR BROKE. IF THE SPLICE BROKE, THE TENSILE VALUE FOR THE LARGEST WIRE ATTACHED TO THE PULL TESTER GR
23、IPS WILL APPLY. * HEAD SPEED PULL RATE: 1 INCH 1/4 INCH PER MINUTE 8.3.3 CURRENT CYCLING (REFERENCE: SAE AS81824 PARAGRAPH 4.8.2): THE CURRENT CYCLING TEST SHALL BE PERFORMED AS FOLLOWS: 8.3.3.1 SAMPLES SHALL BE ATTACHED TO 3 FOOT LENGTH OF THE LARGEST ACCOMMODATED SINGLE WIRE ON ONE SIDE AND MAXIMU
24、M ACCOMMODATED MULTIPLE WIRES ON THE OTHER SIDE. THIS PATTERN SHALL ALTERNATE TO CONNECT THE REQUIRED NUMBER OF SAMPLES PER TABLE 3 OF SAE AS81824 QUALIFICATION INSPECTION. THE CURRENT FOR THE MAXIMUM SINGLE WIRE AS DEFINED IN TABLE 1 OF SAE AS81824 TEST REQUIREMENTS SHALL BE APPLIED FOR THE NUMBER
25、OF CYCLES AND DURATION DEFINED IN 4.8.2 OF SAE AS81824. 8.3.3.2 VOLTAGE DROP SHALL BE MEASURED FOR EACH WIRE AND COMPARED TO THE SOLDERED EQUAL CONFIGURATION AS DESCRIBED IN 8.3.1. 8.3.4 INSULATION RESISTANCE AND DIELECTRIC WITHSTANDING VOLTAGE (REFERENCE: SAE AS81824 PARAGRAPH 4.8.3 AND 4.8.4) MEAS
26、UREMENTS SHALL BE PERFORMED ON THE LAREST WIRE ON EACH SIDE OF THE SPLICE. 9. NOTES: RECOMMENDED WIRE RANGE: TABLE 4 - RECOMMENDED WIRE RANGE (REFERENCE) PART NUMBER MULTIPLE WIRE RANGE CMA (mm2) MULTIPLE WIRE TOTAL OD PER OPENING (OD1+OD2) MAX M81824/10-1 304 1510 (0.15 0.75) 0.093 (2.36) M81824/10
27、-2 1058 2680 (0.53 1.34) 0.093 (2.36) M81824/10-3 2375 6755 (1.19 3.37) 0.093 (2.36) TABLE 5 - TYPICAL CONDUCTOR CMA (REFERENCE) SIZE 26 24 22 20 18 16 14 12 STRANDS 19 19 19 19 19 19 19 37 CMA 304 475 754 1216 1900 2426 3831 5874 (mm2) (0.15) (0.24) (0.38) (0.61) (0.95) (1.21) (1.92) (2.94) AEROSPA
28、CE STANDARD AS81824/10SHEET 4 OF 4 SPLICE, IN-LINE, ELECTRIC, CRIMP, NI/CU, ENVIRONMENTAL, HEAT-SHRINKABLE SLEEVE (175 C), 3 X 3 SEALANT OPENING 10. APPLICATION NOTE 10.1 INTENDED USE: THIS SPLICE IS INTENDED FOR USE IN MAKING ENVIRONMENTALLY PROTECTED PERMANENT JOINTS CONNECTING A MAXIMUM OF SIX WI
29、RES INSERTED IN THREE OPENINGS ON THE SEALANT AND FOR WIRES RATED AT 175 C MINIMUM; TIN COATED CONDUCTORS; AND FALLING WITHIN THE DIAMETER RANGE SPECIFIED IN THIS SPECIFICATION SHEET. WHEN USING MULTIPLE WIRES, REFER TO TABLE 4 AND TABLE 5 IN SECTION 9 FOR CMA RANGES. FOR TERMINATING LESS THAN THREE
30、 WIRES ON ONE SIDE, SEE AS81824/1 FOR 1X1 SEALANT OPENING OR AS81824/7 FOR 1X3 SEALANT OPENING SPLICES. 10.2 SPLICING: SPLICING CONDUCTORS MAY ADVERSELY AFFECT THE WIRE PERFORMANCE IN CERTAIN APPLICATIONS (E.G., HIGH SPEED DATA TRANSMISSION CABLES (FIBRE CHANNEL). USERS MUST EVALUATE THE SUITABILITY
31、 OF THIS SPLICING DEVICE IN THEIR SPECIFIC APPLICATIONS PRIOR TO USE. 10.3 CAUTION: THIS SPLICE IS NOT RECOMMENDED FOR APPLICATION TEMPERATURE ABOVE 175 C. 11. SPECIFICATION NOTE 11.1 A CHANGE BAR (l) LOCATED IN THE LEFT MARGIN IS FOR THE CONVENIENCE OF THE USER IN LOCATING AREAS WHERE TECHNICAL REV
32、ISIONS, 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.
