1、ASD Technical Report Rapport Technique ASD ASD Fachbericht TR 4646 Edition 1 December 2008 PUBLISHED BY THE AEROSPACE AND DEFENCE INDUSTRIES ASSOCIATION OF EUROPE - STANDARDIZATIONAvenue de Tervuren, 270 - B-1150 Brussels - Tel. + 32 2 775 8126 - Fax. + 32 2 763 3565 - www.asd-stan.orgICS: Descripto
2、rs: ENGLISH VERSION Aerospace series Termination procedure for EN 4531 optical contact Srie arospatiale Procdure de cblage pour contact optique EN 4531 Luft- und Raumfahrt Montageanleitung, fr Kontakte nach EN 4531 This Technical Report was drawn up by the Electrical Domain of ASD-STAN. The reason w
3、hich led to the publication of the document as a Technical Report is explained in the foreword. Edition approved for publication 31 December 2008 Electrical Domain Copyright 2008 by ASD-STAN Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permi
4、tted without license from IHS-,-,-Page 2 TR 4646:12-08 Contents Page Foreword2 1 EN 4531-101 contact terminus assembly 3 2 Normative references 3 3 Safety summary .3 4 Cable and fibre preparation3 5 Installation of the EN 4531 contact onto the fibre6 6 Fibre cleave . 11 7 Fibre end polishing. 11 7.1
5、 General definitions before starting. 11 7.2 Coarse polishing. 13 7.3 Fine polishing AUTOMATIC. 13 7.4 Quality check. 13 8 Installation of the terminus into a circular connector. 16 9 Insertion of the EN 4531-101 contact terminus into a rectangular ARINC style connector. 18 Foreword The main task of
6、 ASD-STAN Technical Committees is to prepare EN Standards, in exceptional circumstances however, the publication of Technical Report of one of the following types may be proposed: Type 1, the subject is still under technical development requiring wider exposure; Type 2, a Technical Committee has col
7、lected data of a different kind from that which is normally published as a European Standard. The Electrical Domain decided to publish this document in the form of a Technical Report of type 2 in order to facilitate the updating of this document. Copyright ASD-STAN Provided by IHS under license with
8、 AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 3 TR 4646:12-08 1 EN 4531-101 contact terminus assembly This termination process defines the stages to reach the minimum qualification requirements for the EN 4531 contact in accordance with EN 4531-001. O
9、ther processes could be applied if they conform to the minimum qualification requirements and with common agreement between manufacturer and user. This standard aims at cable termination within manufacturing facility. CAUTION Training and qualification of personnel terminating fibre optic contacts i
10、s mandatory. Throughout the termination process, cleanliness is critical to obtain high optical quality termination. Ensure that work areas are kept as clean as possible to minimize the ingress of dirt into the connector parts. NOTE Verify that the epoxy adhesive shelf life has not expired. Do not u
11、se epoxy adhesive with an expiration date that has passed. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (in
12、cluding any amendments) applies. EN 4531-001, Aerospace series Connectors, optical, circular, single and multipin, coupled by threaded ring Flush contacts Part 001: Technical specification. EN 4531-101, Aerospace series Connectors, optical, circular, single and multipin, coupled by threaded ring Flu
13、sh contacts Part 101: Optical contact for EN 4641-100 cable 55 C to 125 C Product standard. 3 Safety summary The following safety precautions shall be observed: a) Safety glasses shall be worn at all times when handling bare fibres or dispensing epoxy adhesive. b) To reduce the chance of skin contam
14、ination wear suitable disposable gloves i.e. surgical latex gloves. c) Do not touch the ends of the fibre as they may puncture the skin. Wash the hands after handling bare fibre. d) Avoid skin contact with epoxy adhesives. e) Never look directly into the end of a fibre. Before inspecting the end fac
15、e of a fibre, verify that the fibre is not emitting energy or use a microscope with integrated camera. 4 Cable and fibre preparation Step 1 Before termination, clean minimum of 10 cm of the outer jacket of the cable end with a suitable optical quality cleaning solution (for example Isopropyl Alcohol
16、 (IPA) impregnated wipes, or a lint free cloth dampened with the cleaning solution). Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 4 TR 4646:12-08 Cut the cable at an angle to facilitate the install
17、ation of the boot, see Figure 1. No strength member should protrude from the cable end. Figure 1 Cut cable at an angle Step 2 Install the cable marker sleeve and the supplied crimp sleeve, over the simplex cable (single fibre cable). Slide the cable marker sleeve, strain relief boot and the spring b
18、ack from the end of the simplex cable. See Figure 2. Key 1 Wire marker sleeve 2 Simplex cable 3 Spring 4 Strain relief boot Figure 2 Installing cable marker sleeve, strain relief boot and spring 2 FO 123 (Tx) DDFR 1 4 3Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo repr
19、oduction or networking permitted without license from IHS-,-,-Page 5 TR 4646:12-08 Step 3 Mark the simplex cable outer jacket to 20 mm and to 25 mm, mark the cable as shown in Figure 3 below. Dimensions in millimetres Key 1 Mark 2 Optical fibre 3 Buffer 4 Aramid yarn 5 Cable jacket Figure 3 EN 4531-
20、101 contact cable stripping dimensions Step 4 Remove the simplex cable jackets back to 20 mm using the simplex cable stripper and trim the aramid yarn using the strength member shears so that only 1 mm is left from the jacket. NOTE The optimum way to remove the simplex cable jackets is to ring cut t
21、he jacket with the simplex cable stripper and pull the jacket off by hand. Pushing off the simplex cable jacket with a tightly held simplex cable stripper can lead to fibre breakage. WARNING Wear safety glasses when removing the fibre buffer and coating to avoid possible eye injury. Step 5 Mark the
22、buffer at 17 mm. Remove the fibre buffer and coatings back to 17 mm using the buffer stripper. Remove the buffer and coating in small sections approximately 6 mm at a time. NOTE Normally, the buffer and coating are tightly adhered to one another and come off of the fibre at the same time. CAUTION Th
23、e uncoated fibre is in its most vulnerable state. Take extreme care not to damage the fibre. Breakage of any one fibre from this point until the connector is completely assembled will require repetition of this and the following steps in order to maintain approximately equal length of all the fibres
24、 in the cable. 3+ 0 1 2 45 1 17 192083+ 0 1 Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 6 TR 4646:12-08 Step 6 Remove any residual coating material from the bare fibres with a wipe dampened with a
25、 quality optical cleaning solution. Wipe only once from the end of the buffer towards the end of the fibre. NOTE 1 Do not repeatedly wipe the bare fibre, as this will weaken the fibre. NOTE 2 Silicone coated fibres may require additional cleaning to ensure all of the silicone coating has been remove
26、d to ensure proper adhesion within the contact ferrule. 5 Installation of the EN 4531 contact onto the fibre NOTE 1 This procedure describes the process for installing EN 4531 contact onto multimode fibres. Epoxy adhesive is used to secure the fibre in the contact for mating purposes. The manufactur
27、ers cure schedules should be closely followed for maximisation of the polymerisation process. NOTE 2 Step 1 below needs to be accomplished prior to installing the contact onto the simplex cable. Step 1 Pre-heat a suitable curing oven to the required temperature, monitor the temperature using a therm
28、ometer or monitor the integrated temperature gauge. For the cure schedule, the following cure parameters should be applied: Use of Epotek 353ND First polymerization at 90 C for 30 minutes, final polymerization at 125 C for 30 minutes. Use of Aremco 526N black First polymerization at 80 C for 2 hours
29、, final polymerization at 165 C for 4 hours. Figure 4 Examples of epoxy curing oven Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 7 TR 4646:12-08 Step 2 Prepare the approved epoxy adhesive as detail
30、ed in the manufacturers instructions. CAUTION NOTE When using a 2 component epoxy adhesive, slowly mix the two parts together to minimise the introduction of air bubbles until the epoxy adhesive is smooth and uniform. Air bubbles in the epoxy adhesive can lead to connector failure during temperature
31、 extremes. Step 3 Remove the syringe plunger and pour the prepared epoxy adhesive into the syringe body, carefully re-insert the plunger. Allow the syringe to stand vertical until all air bubbles have risen to the surface. WARNING Wear safety glasses while dispensing the epoxy to avoid possible eye
32、injury. Take care not to be injured during the syringe needle use. Step 4 Install the needle onto the syringe and remove excess air pockets in the syringe by holding the tip of the syringe upward and slowly depressing the plunger until the epoxy adhesive runs free and clear from the tip of the syrin
33、ge needle. Step 5 Inspect the contact and verify that the ferrule hole is free and clean of dirt. This can be accomplished by holding the front of the contact up to a light and verifying that the light is visible from the rear of the contact. If light cannot be seen through the contact, carefully pu
34、sh a piece of suitable sized piano wire through the contact hole to clear it. Then blow dry air through the hole to remove any debris. Step 6 Clean with alcohol the ferrule end, to ensure epoxy adhesion on this area. Step 7 Slide the contact, rear first, onto the syringe tip until it bottoms out ins
35、ide the contact. Keeping the syringe vertical, depress the plunger and slowly inject epoxy adhesive into the terminus until a bead of epoxy can be seen on the ferrule end face. See Figure 5. Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permi
36、tted without license from IHS-,-,-Page 8 TR 4646:12-08 Key 1 Contact 2 Syringe filled with epoxy adhesive Figure 5 Injecting epoxy adhesive into the rear of the EN 4531 contact terminus Step 8 Wipe the syringe tip clean using a dry lint free wipe. Step 9 Install the contact onto the fibre by gently
37、working the fibre through the contact until the cable marking is exactly located at the rear of the flange. Protrusion of the fibre shall be 4 mm minimum. See Figures 6 and 7. Key 1 4 mm minimum 2 Bead of epoxy adhesive 3 Marking Figure 6 Mounted contact scheme NOTE The outer cable jacket should com
38、e up to within 1 mm of the rear of the contact and the aramid yarn should be up inside the rear of the contact. 121 2 3Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 9 TR 4646:12-08 Key 1 Outer cable
39、 jacket 2 Contact Figure 7 Installing the contact onto the fibre Step 10 Verify that there is a small amount of epoxy adhesive around the fibre where it protrudes from the ferrule. If it is found that there is no small bead of epoxy adhesive on the contact tip, carefully add a small amount of epoxy
40、around the fibre. See Figure 8. NOTE There should only be a small amount of epoxy adhesive around the fibre to support it during the polishing process. Key 1 Small bead of epoxy Figure 8 Bead of epoxy Step 11 Using a cleaning wipe, carefully wipe away any epoxy adhesive excess on the fibre that is m
41、ore than 2 mm (0.1 in) from the ferrule tip surface. CAUTION Do not get epoxy adhesive on the outside of the ceramic ferrule of the contact. Wipe off any epoxy adhesive excess on the outside of the ceramic ferrule using a lint free cloth. Step 12 Insert contact into the cure adapter until it rests a
42、gainst the section, behind the ceramic ferrule. See Figure 9. 2 1 1 Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Page 10 TR 4646:12-08 Key 1 Terminus 2 Cure adapter Figure 9 Inserting the terminus into
43、a cure adapter Step 13 Repeat steps 5 through 12 for each fibre to be terminated. Step 14 Ensure the oven temperature corresponds to the need. Step 15 Carefully place the contact in the curing oven, and position the cable vertically over the oven. NOTE 1 When the cable is positioned above the contac
44、t, make sure that no bends are introduced into the simplex cables. NOTE 2 Support clamp must be designed to ensure vertical position of the contact into the oven. Key 1 Terminus 2 Cure adapter Figure 10 Curing oven 1 21 2 Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo r
45、eproduction or networking permitted without license from IHS-,-,-Page 11 TR 4646:12-08 Step 16 After completion of the cure schedule remove the contact from the curing oven, and allow to cool down. WARNING Do not touch the contact when removing from the oven as severe burns will be the result. 6 Fib
46、re cleave Step 1 After the contact has cooled down, carefully score the fibre close to the contact tip at the epoxy adhesive interface using one short light stroke with cleaving tool. See Figure 11. Pull off each fibre with a gentle, straight pull. Deposit the waste fibre in a dedicated sharps conta
47、iner. NOTE Protrusion of the fibre shall be 4 mm minimum. If it is not the case, the cable has moved during the curing. The contact must be removed and replaced. Key 1 Fibre epoxy bead 2 Scribe tool 3 Contact Figure 11 Scoring the fibre 7 Fibre end polishing NOTE Automatic polishing process is more
48、reliable and gives better optical results and repeatable end face profiling. WARNING Safety glasses should be worn prior to scribing the optical fibre. 7.1 General definitions before starting NOTE “Place the polishing paper on the support*” means: Step 1 Clean the support with a wipe dampened with alcohol or quality optical cleaning solution. 4 mm min. 1 23Copyright ASD-STAN Provided by IHS under license with AECMA Not for ResaleNo reproduction or networking permitted without license from IHS-,-,-Pag
