1、ASD Technical Report Rapport Technique ASD ASD Fachbericht TR 4648 Edition 1 February 2009 PUBLISHED BY THE AEROSPACE AND DEFENCE INDUSTRIES ASSOCIATION OF EUROPE - STANDARDIZATIONAvenue de Tervuren, 270 - B-1150 Brussels - Tel. + 32 2 775 8126 - Fax. + 32 2 775 8131 - www.asd-stan.orgICS: Descripto
2、rs: ENGLISH VERSION Aerospace series Cable, electrical Re-qualification following changes in design, material or manufacturing process Srie arospatiale Cbles lectriques Re-qualification aprs changement de conception, de matriau ou de processus de fabrication Luft- und Raumfahrt Elektrische Leitungen
3、 Re-Qualifikation infolge von nderungen in Design, Material oder Produktionsprozess This Technical Report was drawn up by the Electrical Domain of ASD-STAN. The reason which led to the publication of the document as a Technical Report is explained in the foreword. Edition approved for publication 28
4、 February 2009 Electrical Domain Copyright 2009 by ASD-STAN Page 2 TR 4648:02-09 Contents Page Foreword3 1 Scope 4 2 Normative references 4 3 Terms and definitions .4 4 Testing requirements 5 4.1 General5 4.2 Changes in conductor material or design.5 4.3 Tests to be performed if change in insulation
5、 material or design6 4.4 Tests to be performed if change on manufacturing machine or process .8 4.5 Selection of cable sizes to be tested .8 Page 3 TR 4648:02-09 Foreword The main task of ASD-STAN Technical Committees is to prepare EN Standards, in exceptional circumstances however, the publication
6、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 collected data of a different kind from that which is normally published as a European Standard. The Electrical Doma
7、in decided to publish this document in the form of a Technical Report of type 2 in order to facilitate the updating of this document. Page 4 TR 4648:02-09 1 Scope This TR provides guidance in defining the tests to be performed, following changes in material, material source, design, or method of man
8、ufacture, to extend the qualification approval of an existing qualified electrical cable. This TR is applicable to all types of cable. The extent of testing required will be dependent on the nature and magnitude of the change. The test programme will be designed to ensure that the cable continues to
9、 comply with key performance requirements. After a cable has been officially qualified it may be necessary, for a variety of reasons, for a manufacturer to request a change to the cable material, cable design or its method of manufacture. The changes may include, but are not limited to, New material
10、; New source of material; New tape dimensions; New manufacturing machine; New manufacturing process. If a manufacturer wishes to implement a change it will be necessary to inform the appropriate mandated body. Discussions will take place between the manufacturer and the mandated body during which th
11、e type and magnitude of the change will be defined and an assessment made of the potential affect it may have on cable performance. Following the discussion a test programme will be agreed. 2 Normative references The following referenced documents are indispensable for the application of this docume
12、nt. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 3475-100*, Aerospace series Cables, electrical, aircraft use Test methods Part 100: General. 3 Terms and definitions For the purposes
13、 of this European Standard, the terms and definitions given in EN 3475-100 apply. *All its parts quoted in this standard. Page 5 TR 4648:02-09 4 Testing requirements 4.1 General It is recognized that changes in material, design or manufacturing process can range significantly from very minor to very
14、 major. During discussions between the mandated body and the supplier to determine the appropriate extent of testing the following general principles will be taken into account: a) If the change is considered major then a full re-qualification to the relevant cable specification will be required by
15、testing the appropriate wire gauges for qualifications defined in Tables 3 and 4. b) If the change is considered minor it is necessary to consider which tests might potentially be affected by the change. A selection of tests is given in the following paragraphs and the final testing schedule shall i
16、nclude the tests considered relevant from these Tables. In addition, after reviewing the relevant cable specification, it might be necessary to conduct other, more specialised, tests as identified by the mandated body, if it is considered possible that the change being considered could impact other
17、performance requirements. All re-qualification reports shall clearly define the nature of the change, qualification results and batch numbers of all cables tested. The proposed change shall not be implemented until the mandated body has reviewed and approved the relevant re-qualification reports. 4.
18、2 Changes in conductor material or design Applicability: the inner conductor ; the cable shielding. Following the assessment of the magnitude of the proposed change the tests to be conducted shall be selected from those defined in Table 1. The number of specimens, test conditions, and requirements s
19、hall be as defined in the applicable technical test or product specifications. Page 6 TR 4648:02-09 Table 1 Tests Carried out on EN 3475- Designation of the test Conductor Finished cable 201 Visual examination X X 202 Mass X X 203 Dimensions X X 301 Ohmic resistance per unit length X X 418 Thermal e
20、ndurance for conductors X 505 Tensile test on conductors and strands X X 506 Plating continuity X 507 Adherence of plating X 508 Plating thickness X 509 Solderability X X 514 Porosity of copper cladding on aluminium strands X 302 Voltage proof test X 303 Insulation resistance X 306 Continuity of con
21、ductors X 401 Accelerated ageing X 402 Shrinkage and delamination X 406 Cold bend test X 504 Torsion X 512 Flexure endurance X 701 Strippability and adherence of insulation to the conductor X 702 Screen pushback capability X 704 Flexibility X 4.3 Tests to be performed if change in insulation materia
22、l or design Applicability: Data transmission or RF cables Only applicable to a modification of the external jacket. Not applicable to the dielectric (in that case, a complete qualification shall be performed). Page 7 TR 4648:02-09 Other cables: Applicable for minor changes of the insulation of singl
23、e wires, or of the component wires of multicore or shielded cables. Applicable to the jacket of cables. Not applicable to major changes such as a modification of the design (thickness of layers, .) or type of material. Such cases require a complete qualification. If the change is considered to be of
24、 minor significance then the tests to be conducted will be selected from the range of tests defined in Table 2. The selection of tests will be made following discussions between the manufacturer and the mandated body and will be those tests where cable performance may have been potentially affected
25、by the proposed change. Table 2 Cable tests relating to material changes EN 3475- Designation of the test 201 Visual examination 202 Mass 203 Dimensions 301 Ohmic resistance per unit length 302 Voltage proof test 303 Insulation resistance 306 Continuity of conductors 401 Accelerated ageing 402 Shrin
26、kage and delamination 403 Delamination and blocking 404 Thermal shock 406 Cold bend test 411 Resistance to fluids 413 Wrap back test 414 Differential scanning calorimeter (DSC test) 501 Dynamic cut-through 502 Notch propagation 503 Scrape abrasion 604 Resistance to dry arc propagation 605 Wet short
27、circuit test 701 Strippability and adherence of insulation to the conductor 703 Permanence of manufacturers marking 704 Flexibility 705 Contrast measurement Page 8 TR 4648:02-09 4.4 Tests to be performed if change on manufacturing machine or process “Prior to delivery test“ and Periodic tests as def
28、ined in the technical specifications of the cables shall be performed. All other tests of concerned specification shall be justified (by similarity or other mean). Additional tests agreed with the mandated body shall also be performed when it is believed that attributes (such as arc tracking) that a
29、re not normally routinely tested may have been compromised All other tests of concerned specification shall be justified (by similarity or other mean). 4.5 Selection of cable sizes to be tested 4.5.1 General The cables to be tested will be determined by the sizes affected by the change and the signi
30、ficance of the change following discussion with the mandated body. As a guide, the sizes for each cable type shall be selected according to the tables in 4.5.2.1 and 4.5.2.2. If only specific gauges or cables are affected, not specifically identified in the tables, then the testing will be conducted
31、 on those gauges. Particular requirements shall be defined with the mandated body. 4.5.2 Cables for general purpose 4.5.2.1 Unshielded cables See Table 3. Table 3 Qualification ranges for unshielded cables Qualified cables Cables covered by the same qualification Nominal cross-section AWG Nominal cr
32、oss-section AWG mm2mm20,15 26 0,25 24 0,25 24 0,15 26 0,6 20 0,4 to 1 22 to 18 2 14 1,2 to 5 16 to 10 9 8 9 to 34 8 to 2 53 0 42 to 107 1 to 0000 Page 9 TR 4648:02-09 4.5.2.2 Shielded cables See Table 4. Table 4 Qualification ranges for shielded cables Qualified cables Cables covered by the same qua
33、lification Nominal cross-section AWG Nominal cross-section AWG Number of conductors mm2mm23 0,15 26 0,25 24 3 0,25 24 0,15 26 1 0,6 20 0,4 to 1 22 to 18 2 2 14 1,2 to 5 16 to 10 4.5.3 Cables other than general purpose cables For cables which are not classed as general purpose cables, such as, but not limited to, data transmission or radio frequency cables, the test programme shall be conducted on each size or type affected by the change.
