1、ASD Technical Report Rapport Technique ASD ASD Fachbericht TR 4647 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 4639 optical contact Srie arospatiale Procdure de cblage pour contact optique EN 4639 Luft- und Raumfahrt Montageanleitung, fr Kontakte nach EN 4639 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 Page 2 TR 4647:12-08 Contents Page Foreword2 1 EN 4639-10* contacts terminus assembly.3 2 Normative reference
4、s 3 3 Safety summary .4 4 Termini contact procedure .4 4.1 EN-4639-101 termini contact procedure4 4.2 EN-4639-102 termini contact procedure.14 5 Fibre cleave . 24 6 Standard polish (multimode fibre) 25 6.1 General. 25 6.2 Coarse polishing (manual). 25 6.3 Fine polishing automatic . 26 7 Quality chec
5、k. 26 7.1 Visual examination . 26 7.2 Interferometer control 29 8 Installation of the terminus into a multipin connector 29 Foreword The main task of ASD-STAN Technical Committees is to prepare EN Standards, in exceptional circumstances however, the publication of Technical Report of one of the foll
6、owing types may be proposed: Type 1, the subject is still under technical development requiring wider exposure; Type 2, a Technical Committee has collected data of a different kind from that which is normally published as a European Standard. The Electrical Domain decided to publish this document in
7、 the form of a Technical Report of type 2 in order to facilitate the updating of this document. Page 3 TR 4647:12-08 1 EN 4639-10* contacts terminus assembly This termination process defines the stages to reach the minimum qualification requirements for the EN 4639-101 terminus onto tight structure
8、simplex fibre optic cable and the EN 4639-102 terminus onto semi-loose structure simplex fibre optic cable using Epo-Tek 353ND epoxy adhesive in accordance with EN 4639-001. Other procedure could be applied if they conform to the minimum qualification requirements and with common agreement between m
9、anufacturers and user. NOTE Two types of termini are described in the following termination processes. It is critical to use the proper termini with the correct type of fibre optic cable: EN 4641-100 cable (2 mm max. tight structure) must use the EN 4639-101 termini. EN 4641-102 cable (2 mm max. sem
10、i-loose structure) must use the EN 4639-102 termini. CAUTION Training and qualification personnel terminating fibre optic contacts are mandatory. Throughout the termination process, cleanliness is critical to obtain a high optical quality contact. Make sure that the hands and work area are as clean
11、as possible to minimise the intake of dirt into the contact parts. NOTE Verify that the epoxy adhesive shelf life has not expired. Do not use epoxy adhesive with an expiration date that has passed. 2 Normative references The following referenced documents are indispensable for the application of thi
12、s document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 4639-001, Aerospace series Connectors, optical, rectangular, modular, multicontact, 1,25 diameter ferrule, with removable ali
13、gnment sleeve holder Part 001: Technical specification. EN 4639-101, Aerospace series Connectors, optical, rectangular, modular, multicontact, 1,25 diameter ferrule, with removable alignment sleeve holder Part 101: Optical contact for cable EN 4641-100 Operating temperature between 65 C and 152 C Pr
14、oduct standard. EN 4639-102, Aerospace series Connectors, optical, rectangular, modular, multicontact, 1,25 diameter ferrule, with removable alignment sleeve holder Part 102: Optical contact for cable EN 4641-102 Operating temperature between 55 C and 100 C Product standard. EN 4641-100, Aerospace s
15、eries Cables, optical 125 m diameter cladding Part 100: Tight structure 62,5/125 m GI fibre 1,8 mm outside diameter Product standard. 1)EN 4641-102, Aerospace series Cables, optical 125 m diameter cladding Part 102: Semi-loose 62,5/125 m GI fibre nominal 1,8 mm outside diameter Product standard. 1)
16、In preparation at the date of publication of this standard. Page 4 TR 4647:12-08 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 contamination wea
17、r 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, always look indirectly at the fibre end
18、after verifying that the fibre is not emitting energy or use a microscope with integrated camera. 4 Termini contact procedure 4.1 EN-4639-101 termini contact procedure 4.1.1 Cable and fibre preparation Step 1 Before termination, clean minimum of 10 cm of the outer jacket of cable end with a suitable
19、 cleaning solution (for example. Isopropyl Alcohol (IPA) impregnated wipes, or a lint free cloth dampened with the cleaning solution). Step 2 Install the cable marker sleeve and supplied crimp sleeve over the simplex cable (single fibre cable). Ensure that the crimp sleeve is installed onto the cabl
20、e rib side first. Slide the crimp sleeve back from the end of the simplex cable. See Figure 1. Key 1 Cable marker sleeve 2 Introduction direction 3 Simplex cable 4 Crimping sleeve 5 Crimping sleeve ribs Figure 1 Installing crimp sleeve NOTE For items 3 to 6 refer to Figure 2 for dimensional informat
21、ion. Introduction direction3 4521 Page 5 TR 4647:12-08 Step 3 Remove the cable jackets back to 23,5 mm using the cable stripper and cut the aramid yarn using the strength member shears so that it is even with the cable jacket. NOTE The optimum way to remove the cable jackets is to ring cut the jacke
22、t with the 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. Step 4 Remove the simplex cable jacket back to 3 mm from outer jacket using the cable stripper. This step will expose the aramid yarn
23、 to the appropriate length. WARNING Wear safety glasses when removing the fibre buffer and coating to avoid possible eye injury. Step 5 Remove the fibre buffer and coatings back to 13 mm from the outer jacket using the buffer stripper. Remove the buffer and coating in small sections approximately 6
24、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 The 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 c
25、ompletely assembled will require repetition of this and the following steps in order to maintain approximately equal length of all the fibres in the cable. Step 6 Remove any residual coating material from the bare fibres with a wipe dampened with a quality optical cleaning solution. Wipe only once f
26、rom the end of the buffer towards the end of the fibre. NOTE 1 Silicone coated fibres may require additional cleaning to ensure the all of the silicone has been removed to ensure proper adhesion within the contact ferrule. NOTE 2 Repeated wiping may weaken the bare fibre. Key 1 Cable outer jacket 2
27、Aramid yarn 3 125 m fibre 4 900 m buffer Figure 2 EN 4639-101 contact cable stripping dimensions 12(3 0,5) mm(26,5 1,5) mm 4 3 (13,5 0,5) mmPage 6 TR 4647:12-08 4.1.2 Installation of the EN 4639-101 terminus onto the fibre This procedure describes the process for installing EN 4639-101 terminus onto
28、 optical fibre. Epoxy adhesive is used to secure the fibre in the terminus for mating purposes. The data described in this document have been validated with Epo-Tek 353ND only. The manufacturers cure schedules should be closely followed for maximisation of the polymerisation process. Step 1 Pre-heat
29、 a suitable curing oven to the required temperature, monitor the temperature using a thermometer or integrated temperature gauge. Step 2 Prepare an approved epoxy adhesive, in accordance with the manufacturers instructions. CAUTION NOTE When using a 2 components epoxy adhesive, slowly mix the two pa
30、rts together to minimize 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 extremes. WARNING Wear safety glasses while dispensing the epoxy to avoid possible eye injury. Follow the manufa
31、cturers recommendations. Step 3 Once the epoxy is mixed, pour into a crucible or any other container. Step 4 Make sure the volumeter counter on the resin injector is set to 2,6 l. If it is not correctly positioned, then turn the knob until it indicates 026 in the volumeter counter window. See Figure
32、 3. Key 1 Resin injector body 2 Injector push button 3 Volumeter knob 4 Volumeter counter window Figure 3 Resin injector and volumeter counter knob 12 3 4 Page 7 TR 4647:12-08 Step 5 Completely depress the injector push button and insert the new piston into the metal fitting of the injector mandrel
33、until it locks into place. Release the injector push button. See Figure 4. Key 1 Metal fitting 2 Resin injector mandrel 3 Injector button depressed 4 Piston Figure 4 Installing the piston into the resin injector mandrel 23 4 1 Page 8 TR 4647:12-08 Step 6 Push the new capillary over the piston until
34、it locks into position on the resin injector mandrel. See Figure 5. Key 1 Resin injector mandrel 2 Capillary Figure 5 Installing the capillary onto the resin injector mandrel 2 1 Page 9 TR 4647:12-08 Step 7 Depress the injector push button and introduce the end of the capillary into the container ho
35、lding the epoxy. Gently release the injector push button to pick up the epoxy until the piston is fully extended. See Figure 6. NOTE Avoid picking up any air bubbles. If air bubbles have been picked up, leave the capillary in the epoxy and push out half the amount of epoxy lifted. Then repeat step 7
36、. Key 1 Injector button depressed 2 Capillary 3 Container holding epoxy Figure 6 Picking up the epoxy into resin injector Step 8 Wipe the capillary and tip clean using a dry lint free wipe. Step 9 Inspect the terminus and verify that the ferule hole is free and clean of dirt. This can be accomplishe
37、d by holding the front of the terminus up to a light and verifying that the light is visible from the rear of the terminus. If light cannot be seen through the terminus, push music wire through the terminus hole to clear it. Then blow dry air through the hole to remove any debris. 213 Page 10 TR 464
38、7:12-08 Step 10 Position the end of the capillary over the end of the ceramic ferule of the terminus. See Figure 7. Key 1 Tip of capillary 2 Terminus ferrule Figure 7 Injecting the epoxy into the terminus ferule Step 11 Press the injector push button gently so that the epoxy is injected into the fer
39、ule hole. Inject all of the epoxy from the resin injector into the terminus. NOTE Ensure the capillary is firmly seated against the ceramic terminus end face prior to injecting the epoxy. Step 12 Keeping the injector push button depressed, lift the capillary away from the terminus end face. Release
40、the push button. NOTE Using a dry lint free cloth, wipe away any excess epoxy from the side of the ceramic ferule and from the ferule end face if the epoxy bead is excessive. Step 13 Install the terminus onto the fibre by gently working the fibre trough the terminus until the buffer seats against th
41、e rear of the terminus. See Figure 8. NOTE The outer cable jacket should come up and touch the rear of the terminus and the aramid yarn should evenly surround the rear of the terminus. 1 2 Page 11 TR 4647:12-08 Key 1 Terminus 2 The rear of the terminus will touch the outer cable jacket 3 Outer cable
42、 jacket Figure 8 Installing the terminus onto the fibre Step 14 Add a drop of epoxy to the crimp area, located at the rear of the terminus. See Figure 9. Key 1 Add drop of epoxy here Figure 9 Adding a drop of epoxy to rear of terminus Step 15 Slide the crimp sleeve up to capture the aramid yarn arou
43、nd the rear of the terminus. See Figure 10. NOTE Verify that the aramid yarn does not protrude excessively from under the crimp sleeve. Aramid yarn protrusion will cause the terminus to not seat properly in the finished connector. If excessive aramid yarn protrudes from under the crimp sleeve, trim
44、it back using strength member shears. Key 1 Aramid yarn 2 Crimp sleeve Figure 10 Sliding up the crimp sleeve 2 13 1 12 Page 12 TR 4647:12-08 Step 16 Verify that there is a small amount of epoxy around the fibre where it protrudes from the ferule. If it is found that there is no small bead of epoxy o
45、n the terminus tip, carefully add a small amount of epoxy around the fibre. See Figure 11. NOTE There should only be a small amount of epoxy around the fibre to support it later during the polishing process. If too much epoxy is around the fibre during the curing process, it may cause damage to the
46、optical glass fibre. Key 1 Small bead of epoxy Figure 11 Bead of epoxy Step 17 Using a wipe dampened with alcohol or quality optical cleaning solution, carefully wipe away any excess epoxy on the fibre that is more than 2 mm from the ferule tip surface. Step 18 Crimp the crimp sleeve using the 2,54
47、mm hex cavity (dye length 10 mm minimum). See Figure 12. Figure 12 EN 4641-101 termini crimp tool (use 2,54 mm cavity) NOTE Make sure to align the 2,54 mm crimp die cavity properly over the crimp sleeve. Do not crimp onto the terminus body. When properly crimped there will not be any flaring of the
48、crimp sleeve. See Figure 13. 1 Page 13 TR 4647:12-08 Key 1 Good crimp. No flaring present on crimp sleeve 2 Bad crimp. Note flares on crimp sleeve Figure 13 Example of good crimp and bad crimp Step 19 Repeat steps 7 through 21 for each fibre to be terminated. Step 20 For Epo-Tek 353ND epoxy adhesive
49、 ensure that the oven temperature is at (9025+) C. CAUTION Do not get epoxy on the outside of the ceramic ferrule of the termini. Wipe off any epoxy excess on the outside of the ceramic ferrule using a lint free cloth. Step 21 Carefully place the terminus in the curing oven, and position the cable vertically over the oven using a suitable cable retention pad. Do not touch the end of the exposed optical fibre
