1、DEPARTMENT OF DEFENSEHANDBOOKGENERAL HANDBOOK FOR SPACEVEHICLE WIRING HARNESS DESIGNAND TESTINGThis handbook is for guidance only.Do not cite this document as a requirementAMSC N/A FSC 1820NOT MEASUREMENTSENSITIVEMIL-HDBK-8357504 JUNE 1998SUPERSEDINGDoD -W- 83575A04 SEP 1992Provided by IHSNot for Re
2、saleNo reproduction or networking permitted without license from IHS-,-,-DOD-HDBK-83575iTABLE OF CONTENTS1. SCOPE 11.1 P URPOSE . . 11.2 A PPLICATION . 12. APPLICABLE DOCUMENTS 12.1 I SSUES OF DOCUMENTS . . 13. REQUIREMENTS . 33.1 O RDER OF PRECEDENCE . . 33.2 S UPPLEMENTARY SPECIFICATIONS AND STAND
3、ARDS . 33.3 S ELECTION OF PARTS , MATERIALS , AND PROCESSES . . 33.4 G ENERAL DESIGN REQUIREMENTS . 43.4.1 Circuit categories. . 43.4.2 Shielding requirements. . 53.4.3 Shield termination and shield grounding. . 63.4.4 Wire terminations. . 83.4.5 Circuit isolation. . 93.4.6 Mockup. 93.4.7 Routing. .
4、 93.4.8 Protection and support. . 103.5 W IRE AND CABLE REQUIREMENTS . 103.6 C ONNECTOR REQUIREMENTS . . 113.7 A SSEMBLY AND FABRICATION REQUIREMENTS . 113.7.1 Fabrication forming board. 113.7.2 Wire lay . 113.7.3 Other requirements. 123.8 H ARNESS IDENTIFICATION AND DATA REQUIREMENTS . . 123.8.1 Wi
5、ring data. . 123.8.2 Identification of individual conductors. . 123.8.3 Identification of harnesses. . 123.9 O PERABILITY . 133.9.1 Reliability. 133.9.2 Interchangeability. . 133.9.3 Maintainability. . 133.9.4 Service life. 133.9.5 Environment. . 133.9.6 Storage and transportability. . 143.9.7 Workm
6、anship 144. QUALITY ASSURANCE REQUIREMENTS 144.1 R ESPONSIBILITY FOR INSPECTIONS AND TESTS . 144.2 C LASSIFICATION OF INSPECTIONS AND TESTS . 144.3. P ARTS , MATERIALS , AND PROCESS CONTROLS . 15Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DOD-HDB
7、K-83575ii4.4 P HYSICAL CONFIGURATION AUDIT . . 154.5 A CCEPTANCE TESTING . 154.5.1 Contact retention test. . 154.5.2 Circuit resistance test. . 164.5.3 Insulation resistance test. 164.5.4 High potential withstanding test. 164.5.5 Insulation resistance retest. . 174.5.6 Contact separation force test.
8、 174.5.7 Environmental testing. . 184.5.8 Acceptance criteria. . 184.6 Q UALIFICATION . . 194.7 M ODIFICATIONS , REWORK AND RETESTING . . 195. PACKAGING (NOT APPLICABLE) . 196. NOTES 196.1 T AILORED APPLICATION . 206.2 D EFINITIONS 206.2.1. Wire. . 206.2.2. Shield. 206.2.3. Cable. . 216.2.4. Cable A
9、ssembly. 216.2.5. Wiring harness. 216.3 S UPERSESSION DATA . 21INDEX22T ABLE 1 S UMMARY O F C IRCUIT C ATEGORIES A ND S HIELDING R EQUIREMENTS . 7T ABLE 2 C ONTACT S EPARATING F ORCE R EQUIREMENTS . 18Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-D
10、OD-HDBK-8357511. SCOPE1.1 Purpose.This handbook sets forth the general design and testing requirements forelectrical wiring harnesses (see 6.2.5) and cable assemblies (see 6.2.4) that areto be installed in space vehicles.1.2 ApplicationThe wiring requirements covered by this handbook are applicable
11、to wiringharnesses and accessories for use in the interconnection of electrical andelectronic equipment in space vehicles. This handbook may also be used tospecify requirements for interconnect wiring on launch vehicles, intercontinentalballistic missiles, or other vehicles (see 6.1). For those appl
12、ications the term“space vehicle” is to be interpreted as the applicable vehicle.2. APPLICABLE DOCUMENTS2.1 Issues of documents.The following documents form a part of this handbook to the extent describedherein.Military Specifications.MIL-C-17 Cables, Radio Frequency; Flexible and Semi-rigid, General
13、 Specification forMIL-W-5088 Wiring, Aerospace VehicleMIL-W-5846 Wire, Electrical, Chromel and/or Alumel, ThermocoupleMIL-C-24308 Connectors, Electric, Rectangular, Minia ture PolarizedShell, Rack and Panel, General Specification forProvided by IHSNot for ResaleNo reproduction or networking permitte
14、d without license from IHS-,-,-DOD-HDBK-835752MIL-C-38999 Connectors, Electric, Circular Miniature, High Density,Quick Disconnect, Environment Resistant, Removable Crimp Contacts, General Specification forMIL-C-39012 Connector, Coaxial, Radio Frequency, GeneralSpecification forMIL-C-55544 Connectors
15、, Electric, Environment Resistant,for Use with Fle xible Flat Conductor Cable and Round Wire, General Specification forMIL-W-81044 Wire, Electric, Crosslinked Polyalkene, CrosslinkedAlkane-imide Polymer, or PolyaryleneInsulated, Copper or Copper AlloyMIL-W-81381 Wire, Electric, Polyimide-Insulated,
16、Cop per or CopperAlloyMIL-C-83723 Connectors, Electric, Circular, (EnvironmentResisting), Receptacles and Plugs, GeneralSpecification forMIL-C-83733 Connectors, Electrical , Miniature, Rectan gular Type, Rack to Panel, Environment Resisting, 200 degrees Total Continuous operating Temperature, Genera
17、l Specification forMilitary StandardsMIL-STD-863 Wiring Data, Preparation ofMilitary HandbooksMIL-HDBK-216 R-F Transmission Lines and Fittings(Copies of specifications, standards, drawings, and publi cations required bycontractors in connection with specific procurement functions be obtained fromthe
18、 contracting office or as directed by the contracting officer.)2.2 Other publications.The following documents form a part of this handbook to the extent describedherein.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DOD-HDBK-835753THE INSTITUTE OF E
19、LECTRICAL AND ELECTRONICS ENGINEERSIEEE 200 -1975 Reference Designations for Electrical and Electronics Parts and Equipments (with ANSI Y32.16 -1975)(Application for copies be addressed to the Institute of Electrical and ElectronicsEngineers. Inc., 345 East 47th street, New York, New York 10017)3. R
20、EQUIREMENTS3.1 Order of precedence .In the event of conflicts between any of the documents referenced herein andthe contents of this handbook, the contents of this handbook should beconsidered the superseding requirements.3.2 Supplementary specifications and standards.When this handbook and the docu
21、ments referenced herein fail to provide asuitable reference, other appropriate documents may be used. If the documentsreferenced in this handbook do not provide the contractually required reliability,quality level, or technical performance, they be interpreted as being referencedto limit the variety
22、 of the physical and functional parameters to the extentpracticable. In those cases, the referenced specifications be the basis ofcontractor specifications that would add, delete, or change specificrequirements. When a detail or general military specification exists for the classof material required
23、, the contractors specification should reference the existingmilitary specification and set forth only the needed new requirements anddeviations. If required by the contract, the supplementary specifications that areprepared by the contractor should be submitted to the contracting officer forreview
24、or approval prior to their use. When required by the contracting officer,the contractor should provide data substantiating the supplementaryrequirements and should provide samples for testing. The use of contractorsspecifications should not constitute waiver of Government inspectionrequirements.3.3
25、Selection of parts, materials, and processes .Unless otherwise specified in the contract, the parts, materials, and processesshould be selected and controlled in accordance with contractor establishedand documented procedures to satisfy the specified wiring harnessrequirements. The selection and con
26、trol procedures should emphasize qualityand reliability, as required, to minimize total life cycle costs for the applicablevehicles. An additional objective in the selection of parts should be to maximizecommonality and minimize the variety of wiring components and relatedProvided by IHSNot for Resa
27、leNo reproduction or networking permitted without license from IHS-,-,-DOD-HDBK-835754servicing tools required in the fabrication, installation, and maintenance of thevehicle electrical wiring system.3.4 General design requirements3.4.1 Circuit categories .The electrical characteristics required for
28、 interconnecting wiring are the firstconsideration to be established in designing electrical wiring harnesses forspace vehicles. In particular, the wire types (see 6.2.1) required depend uponthe voltage, current capacity, and frequency of the circuits. The five majorcategories and the various subcat
29、agories of circuits are defined in the followingsubparagraphs and summarized in Table I. Each circuit in each wiring harnessor cable assembly should be categorized in accordance with these definitions.3.4.1.1 Category I (power and control).Includes (a) dc circuits over 10 volts (V), (b) dc circuits
30、below 10 V and over 5amperes (A), (c) ac circuits below 0.1 megahertz (MHz) with voltages above 25V rms, and (d) pulse circuits with maximum voltages above 25 V with rise and falltimes greater than 1 microsecond.3.4.1.2 Category II (high-level signals).Includes (a) digital circuits with voltage leve
31、ls from 5 to 25 V maximum and riseand fall times greater than 1 microsecond, (b) digital circuits with maximumvoltage levels from 1 to 10 V and rise or fall times less than 1 microsecond, (c)ac circuits below 0.1 MHz with voltages between 5 V and 25 V, and (d) accircuits between 0.1 MHz and 1.0 MHz
32、with voltage levels between 1 V and 10V.3.4.1.3 Category III (low-level signals)Includes (a) dc circuits below 10 V and less than 5 A, (b) ac circuits between 0.1MHz and 1.O MHz with voltage levels less than 1 V, (c) ac circuits below 0.1MHz with voltages less than 5 V, (d) digital circuits with max
33、imum voltages lessthan 1 V and with rise or fall times less than 1 microsecond, and (e) digitalcircuits with maximum voltages less than 5 V and with rise and fall times greaterthan 1 microsecond.3.4.1.4 Category IV (electroexplosive device circuits).Includes all electroexplosive device (EED) circuit
34、s.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-DOD-HDBK-8357553.4.1.5 Category V (high-frequency signals).Includes (a) all ac circuits above 1 MHz and (b) high-level digital circuits withmaximum voltages above 10 V and with rise or fall times less
35、 than 1microsecond, and (c) ac circuits between 0.1 MHz and 1.0 MHz with voltagelevels above 10 V.3.4.2 Shielding requirements .Shielding (see 6.2.2) should be provided as indicated in the followingsubparagraphs. All shielding should be insulat ed to prevent uncontrolledgrounding.3.4.2.1 Interconnec
36、t wiring for category I circuits.Wiring for category I circuits should have the power or signal wire(s) twisted withthe return wire. The wiring may be unshielded.3.4.2.2 Interconnect wiring for category II circuits.Wiring for category II circuits should have twisted signal and return wires witheach
37、pair, or circuit, shielded.3.4.2.3 Interconnect wiring for category III circuits.Wiring for category IIIa should have twisted signal and return wires. CategoryIIIa wiring should be shielded as a group from category IIIb and other categories.Wiring for category IIlb should have twisted signal and ret
38、urn wires with eachpair, or circuit, shielded. Wiring for category IIIc should have twisted signal andreturn wires. Category IIIc wiring should be shielded as a group from categoryIlIa, IIIb, and other categories. Wiring for category IIId and category IIIe shouldhave twisted signal and return wires
39、with each pair, or circuit, shielded.3.4.2.4 Interconnect wiring for category IV circuits.Wiring should be twisted pairs, each pair shielded.3.4.2.5 Interconnect wiring for category V circuits.Wiring interconnections, other than waveguide, should be shielded coaxialcable, balanced shielded cable, or
40、 balanced cable with a characteristicimpedance of 100 ohms or less.3.4.2.6 Added shielding .Shielding can be added over that specified for the category of each circuit toprevent excessive radiation from, or excessive pickup on, the circuit. Coax orProvided by IHSNot for ResaleNo reproduction or netw
41、orking permitted without license from IHS-,-,-DOD-HDBK-835756balanced shielded cable may be used instead of twisted shielded pairsparticularly in applications where the capacitance per meter is critical. Shieldingshould be added over that specified for the category of each circuit to the extentrequi
42、red when an electromagnetic pulse (EMP ) environment is specified.Shielded circuits may be routed together in a bundle with a common secondaryshield.3.4.3 Shield termination and shield grounding .Multiple point shield grounding should be used on high -frequency circuits ( above0.1 MHz), on digital c
43、ircuits with rise or fall times less than 1 microsecond, andon all EED firing circuits (category IV). Single end shield grounding should bemaintained on all other circuits, except that when multiple shields are used toprevent induced interference, the outer shield should be multipoint grounded.When
44、single end shield grounding is used to protect a circuit against inducedradiation, the ground should be at the receiver or high impedance end. Whensingle end shield grounding is used to minimize radiation from a circuit, theground should be at the signal source end.3.4.3.1. Shield terminations for e
45、lectromagnetic pulse (EMP) environment.Wire shields in all categories of circuits that may be subjected to an EMPenvironment should be bonded around the circumference, and preferably withinthe backshell, of the connectors. Inner shields that are designed to beungrounded at one end should be terminat
46、ed within the connector shell and theends secured against fraying. Ungrounded inner shield terminations should beinsulated from the connector pins, the backshell of the connector, and fromadjacent shields.3.4.3.2 Shield ground terminations for category IV circuits.Wire shields in category IV circuit
47、s (EEDs) should be bonded around thecircumference, and preferably within the backshell of the connectors. Circuitssuch as pyrotechnic event instrumentation circuits that make a direct connectionto the electroexplosive device circuit should employ shields which are bondedaround the circumference and
48、preferably with the backshell at the pyro junctionor relay box connector. If an EMP environment is not specified, the shield groundat the other instrumentation circuit connector may be grounded through a pigtailto a pin in the connector or directly to structure.Provided by IHSNot for ResaleNo reprod
49、uction or networking permitted without license from IHS-,-,-DOD-HDBK-835757Table 1 Summary Of Circuit Categories And ShieldingRequirementsCircuit Character LevelVolts (V)orAmperes (A)Category(see 3.4.1)Shielding(see 3.4.2)Direct current Below 10 V andless than 5 AIIIa shielded as a groupfrom other categoriesBelow 10
