1、 AEROSPACE STANDARD SPLICE, IN-LINE, ELECTRIC, CRIMP, SN/CU, ENVIRONMENTAL, HEAT-SHRINKABLE SLEEVE (150 C), 1 X 3 SEALANT OPENING AS81824/7Copyright 2017 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、.sae.org ISSUED 2012-07REAFFIRMED 2017-06THIRD ANGLE PROJECTION CUSTODIAN: AE-8/AE-8C2 FEDERAL SUPPLY CLASS 5940 AS81824/7 SHEET 1 OF 4 PROCUREMENT SPECIFICATION: AS81824/7 SAETechnicalStandardsBoard Rulesprovidethat:“Thisreportispublished bySAEto advance the state oftechnicaland engineeringsciences
4、.The use ofthisreportisentirelyvoluntary,anditsapplicabilityandsuitabilityforanyparticularuse,includinganypatentinfringementarising therefrom,isthe sole responsibilityoftheuser.”SAEreviewseachtechnicalreportatleastevery fiveyearsatwhich time itmaybe revised,reaffirmed,stabilized,orcancelled.SAEinvit
5、esyourwritten commentsandsuggestions.SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AS81824/7 RATIONALE AS81824/7 HAS BEEN REAFFIRMED TO COMPLY WITH THE SAE FIVE-YEAR REVIEW POLICY. NOTICE THE COMPLETE REQUIREMENTS FOR PROCURING SPLICE DESCR
6、IBED 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 M81824/7-1 SEE TABLE 4 .053 (1.35) .045 (1.14) .080 (2.03) .075 (1.91) .510 (12.95) .490 (12.45) .245 (6
7、.22) .225 (5.72) .015 (0.38) RED 5.30 (2.4) M81824/7-2 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 5.85 (2.7) M81824/7-3 SEE TABLE 4 .103 (2.62) .095 (2.41) .155 (3.94) .146 (3.71) .585 (14.86) .565 (14.35) .280 (7.11
8、) .260 (6.60) .050 (1.27) YELLOW 6.85 (3.1) *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 SPECIFIED, TOLERANCES ARE .005 (0.13 MM) FOR THREE PLACE DECIMALS .01 (0.25
9、 MM) FOR TWO PLACE DECIMALS INSPECTION WINDOW WIRE STOP STRIPE COLOR CODES IN ACCORDANCE TO TABLE 1 SEALING SLEEVE 1.100 0.050 0.600 MINIMUM0.093 MIN 0.160 MIN* B C D TYPICAL .110 .080AMETAL CRIMP SPLICE E AEROSPACE STANDARD AS81824/7 SHEET 2 OF 4 SPLICE, IN-LINE, ELECTRIC, CRIMP, SN/CU, ENVIRONMENT
10、AL, HEAT-SHRINKABLE SLEEVE (150 C), 1 X 3 SEALANT OPENING REQUIREMENTS: MATERIAL: METAL CRIMP SPLICE: COPPER PER ASTM B280, ASTM B75-68, ASTM B187, ASTM B1 OR ASTM B152 INSULATION SLEEVE: HEAT SHRINKABLE, TRANSPARENT POLYVINYLIDENE FLUORIDE PER THE PERFORMANCE REQUIREMENTS OF SAE AS23053/8. SEALING
11、MATERIAL: MODIFIED THERMOPLASTIC, SEE PROCUREMENT SPECIFICATION. FINISH: METAL TIN PLATED PER ASTM B545. 1. CONTOUR: CONTOUR MAY VARY FROM THAT SHOWN. 2. AVERAGES OF DIAMETERS “A” AND “B” OF THE INSPECTION SAMPLES MUST BE WITHIN SPECIFIED LIMITS. 3. “B” DIAMETER SHALL NOT INCLUDE COLOR STRIPE. 4. NO
12、 ETCHING OR SOLVENT TREATING OF THE ASSOCIATED WIRE INSULATION SHALL BE PERMITTED. 5. RESERVED 6. RESERVED 7. RESERVED 8. QUALIFICATION: QUALIFICATION SHALL BE TESTED IN ACCORDANCE WITH SAE-AS81824. SEE 8.3 FOR EXCEPTIONS. 8.1 TERMINATION TOOL: FOR QUALIFICATION TESTING, ONLY SPLICE ASSEMBLIES MADE
13、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 TOOL. FOR CRIMPING TOOLS, SEE TABLE 2. TABLE 2 - CRIMP TOOLS SPLICE PART NO. BASIC CRIMP TOOL NO. DIE NO. M81824/7-1 M81824/7-2 M22520/5-01 M22520
14、/10-01 M22520/37-01 M22520/5-103 M22520/10-104 N/A M81824/7-3 M22520/5-01 M22520/10-01 M22520/37-01 M22520/5-102 M22520/10-103 N/A 8.2 WIRE RANGE: TABLE 3 LISTS TYPICAL WIRE RANGES FOR EACH SPLICE SIZES. FOR MULTIPLE CONDUCTOR SPLICING, DETERMINE THE PROPER CRIMP BARREL SIZE BASED ON TOTAL CONDUCTOR
15、 MIL AREA (CMA) OR CONDUCTOR AREA IN MM2 FOR EACH SIDE. TABLE 3 - QUALIFICATION SPLICE CONFIGURATION PART NUMBER MULTIPLE WIRE SIZE (QTY) ON SINGLE SEALANT OPENING SIDE MULTIPLE WIRE SIZE (QTY) ON THREE SEALANT OPENING SIDE MIN SAMPLE WIRE SIZE MAX SAMPLE COMBINATION MIN SAMPLE COMBINATION /1 MAX SA
16、MPLE COMBINATION M81824/7-1 26 26(1) + 24(1) 26(2) 26(3) + 24(1) M81824/7-2 20 22(1) + 20(1) 26(1) + 22(1) 26(1) + 24(5) M81824/7-3 16 22(1) + 12(1) 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 AS8
17、1824 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 PUNCTU
18、RING THE LARGEST WIRE INSULATION ON BOTH SIDES OF THE CRIMP 1/16 INCH BACK FROM THE ENDS OF THE SEALING SLEEVE. AEROSPACE STANDARD AS81824/7 SHEET 3 OF 4 SPLICE, IN-LINE, ELECTRIC, CRIMP, SN/CU, ENVIRONMENTAL, HEAT-SHRINKABLE SLEEVE (150 C), 1 X 3 SEALANT OPENING 8.3.2 TENSILE STRENGTH (REFERENCE: S
19、AE 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 O
20、R 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 PULL
21、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 O
22、NE OF THE WIRES OR BREAK THE SPLICE. * HEAD SPEED PULL RATE: 1 INCH 1/4 INCH PER MINUTE 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 FO
23、R THE LARGEST WIRE ATTACHED TO THE PULL TESTER GRIPS WILL APPLY. 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 MAXIMUM
24、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 OF
25、 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) MEASUR
26、EMENTS 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 SINGLE WIRE /1 MULTIPLE WIRE TOTAL ODSINGLE SEALANT SIDE (OD1+OD2) MAX MULTIPLE WIRE RANGE CMA (mm2) MULTIPLE WIRE TOTAL OD PER OPENING
27、(OD1+OD2) MAX M81824/7-1 26-24-22-20 0.085 (2.16) 304 1510 (0.15 0.75) 0.093 (2.36) M81824/7-2 20-18-16 0.110 (2.79) 1058 2680 (0.53 1.34) 0.093 (2.36) M81824/7-3 16-14-12 0.170 (4.32) 2375 6755 (1.19 3.37) 0.093 (2.36) /1 FOR OVERLAPPING WIRE SIZES (E.G., SIZE 20 FOR M81824-1 AND M81824-2 AND SIZE
28、16 FOR M81824-2 AND M81824-3), THE SMALLER SIZE SPLICES ARE PREFERRED (I.E., FOR SIZE 20 AND SIZE 16 WIRES, M81824-1 AND M81824-2, RESPECTIVELY, ARE PREFERRED). 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 383
29、1 5874 (mm2) (0.15) (0.24) (0.38) (0.61) (0.95) (1.21) (1.92) (2.94) AEROSPACE STANDARD AS81824/7 SHEET 4 OF 4 SPLICE, IN-LINE, ELECTRIC, CRIMP, SN/CU, ENVIRONMENTAL, HEAT-SHRINKABLE SLEEVE (150 C), 1 X 3 SEALANT OPENING 10. APPLICATION NOTE 10.1 INTENDED USE: THIS SPLICE IS INTENDED FOR USE IN MAKI
30、NG ENVIRONMENTALLY PROTECTED PERMANENT JOINTS CONNECTING A MAXIMUM OF TWO WIRES INSERTED IN ONE OPENING SEALANT SIDE AND A MAXIMUM OF SIX WIRES INSERTED IN THREE OPENING SEALANT SIDE OF THE SPLICE AND FOR WIRES RATED AT 150 C MINIMUM; TIN COATED CONDUCTORS; AND FALLING WITHIN THE DIAMETER RANGE SPEC
31、IFIED IN THIS SPECIFICATION SHEET. WHEN USING MULTIPLE WIRES, REFER TO TABLE 4 AND TABLE 5 IN SECTION 9 FOR CMA RANGES. 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
32、 THE SUITABILITY OF THIS SPLICING DEVICE IN THEIR SPECIFIC APPLICATIONS PRIOR TO USE. 10.3 CAUTION: THIS SPLICE IS NOT RECOMMENDED FOR APPLICATION TEMPERATURE ABOVE 150 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 WHE
33、RE 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.
