1、CEN PREN*Z242 91 3404589 OE!flIJl 7 1 A. E, C. M. A. STAN DARD prEN 2242 NORME A.E.C.M.A. issue P 1 A.E.C.M.A. NORM October 1991 DITE PAR LASSOCIATION EUROPENNE DES CONSTRUCTEURS DE MATERIEL AROSPATIAL Technopolis - 175, rue Jean-Jacques Rousseau - F-92138 Issy-les-Moulineaux Cdex - Tl. 11) 47.36.98
2、.76 UDC : 621.325 : 629.7 Key words : Aircraft industry, aircraft equipment, cable, crimping ENGLISH .VERSION Aerospace series Control of tools used for crimping of electric cables with conductors defined by EN 2083 and EN 2346 Sri- arospatiale Luft- und Raumfart Contrle des outils utiliss pour le s
3、ertissage des cbles lectriques avec mes dfinies par EN 2083 et EN 2346 Prfung von Werkzeugen fr das Crimpen von elektrischen Leitungen mit Leitern nach EN 2083 und EN 2346 This Aerospace Seriem pre-standard has been drawn up under the responsibility of AECMA (Association Europenne des Constructeurs
4、de Matriel Arospatial). It is published on green paper for the needs of AECMA-Members. It has been technically approved by the experts of the concerned Commission following comment by the Member countries. Subsequent to the publication of this pre-standard, the technical content shall not be changed
5、 to an extent that interchangeability is affected, physically or functionally, without re-identification of the standard. After examination and signature of the AECMA Standard Checking Centre (NPS) and formal agreement of the Official Services of the Member countries it will be submitted as a draft
6、European Standard to CEN (European Committee for Standardization) for final vote. Mola -Extra copies can be supplied by B.N.A.E. - Technopolis 54 - 199, rue Jean-Jacques Rousseau - 92138 ISSY-LES-MOULINEAUX CEDEX Edition approved for publication Comments should be sent within six months C2 Chairman
7、after the date of publicafion decision 1 991 -1 0-1 8 A.E.C.M.A. MI. LE CUNFF Technopolis - 175, rue Jean-Jacques Rousseau 92138 Issy-les-Moulineaux Cdex - FRANCE 0 aecrna T991 Copyright Association Europeene des Constructeurs de Materiel Aerospatial Provided by IHS under license with AECMANot for R
8、esaleNo reproduction or networking permitted without license from IHS-,-,-r CEN PREN*2242 i1 3404589 O020002 9 I prEN 2242 Page 2 6 QB O a CONTENTS 1 2 References 3 Terminology 4 General requirements for crimping 5 6 7 Quality assurance Annex A (normative) : Correct crimped connections Annex B (norm
9、ative) : Faulty crimped connections (examples) Scope and field of application Materials and tooling to be used Check before execution of wiring Copyright Association Europeene des Constructeurs de Materiel Aerospatial Provided by IHS under license with AECMANot for ResaleNo reproduction or networkin
10、g permitted without license from IHS-,-,-CEN PRENS2242 91 3404589 0020003 0-E prEN 2242 Page 3 I 1 This standard defines the visual and mechanical inspection oDerations to be carried out Scope and field of application O to ensure the good quality of crimped connections made with multi-stranded cable
11、s whose conducting section goes from 0,15 mm2 (gauge 261 to 107 mmZ (gauge 0000), on all types of end components. The quality of a crimped connection depends upon the maintenance and control of cutting, stripping and crimping tools. To this end, this document gives the principle requirements as far
12、as tooling and methods to be used are concerned for carrying out correct crimpings. For the other tests, it is necessary to refer to the product standard which shall refer to the tests defined in EN 2591. Electric cables to be used for the tests shall conform to EN 2084, EN 2234, EN 2235 and be stri
13、pped according to EN 281 2. 2 References IEC 50 (581) EN 2083 EN 2084 EN 2234 EN 2235 EN 2346 EN 2591 EN 2591-DI7 EN 2591-E3 International Electrotechnical Vocabulary - Chapter 58 I : Electromechanical components for electronic equipment Copper and copper alloy conductors for electrical cables - Aer
14、ospace series 1) Electric cables for general purpose with conductors in copper or copper alloy - Technical specification - Aerospace series 1 ) Aerospace series - Fire-resistant electrical cables - Technical specification 2) Aerospace series - Single and multicore electrical cables screened and shea
15、thed - Technical specification 2) Aerospace series - Dimensions, conductor resistance and mass of fire- resistant electrical cables 3) Aerospace series - Elements of electrical and optical connection - Test methods - General 1) Aerospace series - Elements of electrical and optical connection - Test
16、methods - Part DI7 - Tensile strength (crimped connection) 2) Aerospace series - Elements of electrical and optical connection - Test methods - Part E3 - Contact deformation after crimping 2) EN 2812 Aerospace series - Stripping of electric cables as defined by standards EN 2084, EN 2234, EN 2235 an
17、d EN 2346 3) 1) Published as AECMA standard at the date of publication of the present standard. 2) In preparation at the date of publication of the present standard. 3) Published as AECMA pre-standard at the date of publication of the present standard. O Copyright Association Europeene des Construct
18、eurs de Materiel Aerospatial Provided by IHS under license with AECMANot for ResaleNo reproduction or networking permitted without license from IHS-,-,-CEN PREN*2242 91 W 3404589 0020004 2 W prEN 2242 Page 4 3 Terminology See IEC 50 chapter 581. Crimping mechanism Mechanism controlling the total cri
19、mping cycle ; fitted wtLh a device which prevents t,e tool from returning to open position before the complete execution of this cycle. Test sample The test sample consists of a length of terminated cable. The test sample shall be identified as well as the tooling used. 4 General requirements for cr
20、imping In particular cases where the crimping of two conductors in a barrel is authorised and qualified, the sum of the two cross sections of the conductors shall be compatible with the section permitted by the barrel. The stripping shall conform to EN 281 2. The crimping of the conductor shall be o
21、btained in a single operation with the aid of the appropriate tooling as approved by the manufacturer of the terminal, contact or splice. This operation does not require any additional heating or cooling to accomplish. No operation such as brazing, complementary operation, etc. shall be carried out
22、on a crimped connection. The organization and preparationof the work station shall be such that the tooling is maintained constantly in good condition and that a check may be made that only the tools and accessories adapted to this type of crimping are used and that there is no modification of the a
23、pplicable regulations (example : the systematic verification of samples). During handling and transport, the crimped connections shall not be subjected to any stress likely to cause deterioration. In addition to the cable cross section being compatible with the crimp barrel, it shall also be within
24、the limits defined in the specification for the connector, terminal or splice and tooling being used. 5 Materials and tooling to be used The materials used in the manufacture of the connection components shall be compatible with the tooling conforming to the standards or specifications in force, so
25、as to respect the characteristics of the connection component and avoid all abnormal damage of the crimping tools. Copyright Association Europeene des Constructeurs de Materiel Aerospatial Provided by IHS under license with AECMANot for ResaleNo reproduction or networking permitted without license f
26、rom IHS-,-,-CEN PREN*2242 71 = 3404587 O020005 4 prEN 2242 Page 5 The crimping tools and their accessories shall be approved by the user or the national O approval authority. It is necessary to verify that the combination “conductor - barrel - tools“ properly complies with the conditions of executio
27、n of the wiring to be made. 6 Before the start of manufacture, prepare test pieces for each combination of barrel, cable and tooling intended to be subjected to checking processes. 6.1 Checking of tooting Before each time the tooling is used or after return from repair the checking of the stripping
28、tools is carried out according to EN 2812. Make sure that the former have been subject to a check by an inspection department or authorised metrology department. It is certified by punching, stamp or sealing. The date of the last inspection and duration of limit of use before a new examination by th
29、e inspection department or authorised metrology department are indicated on the tooling or the corresponding tooling record card. In addition check that the crimping mechanism is functioning correctly. Check before execution of wiring O 6.2 Preparation of components to be assembled 6.2.1 General cas
30、e Check that the connection components and the cabte conform to the definition documentation and their characteristics are appropriate to the tooling to be used. Check that the inspection of connection components and the cable to be connected has been correctly carried out and that if necessary the
31、storage conditions are correct. The connection components shall be clean, free from any trace of corrosion and shall not show any defects. However, a slight uniform and superficial discoloration is tolerated. The cable shall be correctly stripped in accordance with EN 28 12 ; the length of the strip
32、ping shall correspond with the manufacture documentation. e 6.2.2 Crimping of multiple conductors in the exceptional crimping case of two conductors in one barrel, a lug or extension piece, the following conditions are to be observed : -the sum of the two actual sections of the crimping of the condu
33、ctors shall be compatible with the section permitted by the barrel ; - the lengths of stripping of the ends of the cable shall be identical ; - all the strands of the conductors, placed parallel to one other, shall enter easily into the barrel ; - the crimping operation shall not cause any offset of
34、 one conductor in relation to the other. Copyright Association Europeene des Constructeurs de Materiel Aerospatial Provided by IHS under license with AECMANot for ResaleNo reproduction or networking permitted without license from IHS-,-,-CEN PREN*2242 31 M 3404583 O020006 6 prEN 2242 Page 6 6.3 Crim
35、ping test pieces The test pieces to be made are made only with the components and under the specified conditions in manufacture, by means of a barrel crimped at each end of the test piece. The test is carried out with 5 test pieces at the minimum section and 5 test pieces at the maximum section for
36、qualification tests. Additional test pieces are necessary if one of the following conditions changes : - material of elementary strands of the conductors ; - metallic covering of strands : tin plating, silver or nickel plating ; - cutting of connection barrels ; - types of tools used, with correspon
37、ding accessories. 6.4 Visual inspection of crimpings carried out on test pieces Carry out a 100 % visual inspection on the crimpings (see annexes A and B) and check : -that the form and location of the crimpings are correct, for example see product standard ; -that the length of stripping is correct
38、 and that the strands of the conductor are all inserted correctly in the barrel (core visible through the inspection hole) ; - that the distance between the insulator of the cable and the barrel shall be such that no bending of the cable can exert stress in the area of the barrel ; - that the core a
39、t the rear of the barrel is not deformed ; - that the connection component shows no defects and no burr, sharp edge, crack or lift off of the protection, or distortions conforming with EN 2591-E3. Sanction : if the inspection is not satisfactory, the connection parts, or the tooling are to be revise
40、d. 6.5 Tensile test Each test piece having satisfied the preceding inspections is submitted to the tensile test characterised by the force exerted in the axial direction of the conductor, test in accordance with EN 2591 -DI 7. The test is continued until the destruction of the test piece. Sanction :
41、 if one of the crimped connections is fractured at a value lower than that specified in the table, the connection parts or tooling are to be reviewed. Copyright Association Europeene des Constructeurs de Materiel Aerospatial Provided by IHS under license with AECMANot for ResaleNo reproduction or ne
42、tworking permitted without license from IHS-,-,- CEN PRENM2242 91 3404589 O020007 8 prEN 2242 Page 7 6.6 Removal of insulaion support Insulation support shall be rendered ineffective, before th tensile test is carried out. Table 1 - Minimum tensile strength of crimped joints according to cross secti
43、on of conductors Nominal sections . of conductors mm2 0,15 1) 0,25 1) O ,40 0,60 1 ,o0 1,20 2,oo 3/00 5,OO 9,oo 14,OO 22,oo 34,OO 42,OO 53,OO 68/00 85,O 107,OO 1 ) High strength copper alloy ( Correspondin AWG 21 gauges 26 22 20 18 16 14 12 10 8 6 4 2 1 O 00 O00 24 - 0.oo nductors Vlinimum tensile s
44、trength of crimp N 39 55 7 Quality assurance 60 90 150 180 300 450 700 1080 1540 1980 2720 3200 4200 5300 . 6400 - 8400 2) AWG : American Wire Gage 7.1 Production controls Check the points enumerated in 6.4 to 100 %. 7.2 Periodic inspections According to the size of the set of parts in manufacture a
45、nd/or the quality requirements, the Inspection Department can check the points enumerated in 6.4 and 6.5. The check is then carried out between 1000 and 5000 crimpings, or each quarter, according to the experience acquired by the user, with a minimum of 2 test samples at the mnimm section and at lea
46、st 2 test samples at the maximum section of the cable. Notwithstanding the values specified in the above table, the tensile strength test may be limited to 500 N for ali sections equal to or- greater than 5 mmz, if authorised by national approval authority, when carrying out periodic qualification t
47、ests on crimp tools. Copyright Association Europeene des Constructeurs de Materiel Aerospatial Provided by IHS under license with AECMANot for ResaleNo reproduction or networking permitted without license from IHS-,-,-CEN PREN82242 91 = 3404589 O020008 T prEN 2242 Page 8 Annex A (normative) Correct
48、crimped connections Checks to be carried out : - strands apparent in the inspection hole ; - correct stripping of insulator ; - insulator correctly positioned ; - indentation correctly positioned ; - non-distorted contacts ; - no cracks or lift off of protection. Copyright Association Europeene des
49、Constructeurs de Materiel Aerospatial Provided by IHS under license with AECMANot for ResaleNo reproduction or networking permitted without license from IHS-,-,-CEN PRN*i242 91 3404589 0020007 I = j I prEN 2242 Page 9 -. Annex B (normative) Faulty crimped connections (examples) , I 4.1 I I , - Insulation stripping too long Insulation stripping too short and crimping on the insulator Cond
