1、BRITISH STANDARDBS EN 50389:2005Space product assurance Wire-wrapping of high-reliability electrical connectionsThe European Standard EN 50389:2005 has the status of a British StandardICS 49.060g49g50g3g38g50g51g60g44g49g42g3g58g44g55g43g50g56g55g3g37g54g44g3g51g40g53g48g44g54g54g44g50g49g3g40g59g38
2、g40g51g55g3g36g54g3g51g40g53g48g44g55g55g40g39g3g37g60g3g38g50g51g60g53g44g42g43g55g3g47g36g58Licensed Copy: Wang Bin, na, Mon Mar 13 07:18:31 GMT 2006, Uncontrolled Copy, (c) BSIBS EN 50389:2005This British Standard was published under the authority of the Standards Policy and Strategy Committee on
3、 21 December 2005 BSI 21 December 2005ISBN 0 580 47003 2National forewordThis British Standard is the official English language version of EN 50389:2005.The UK participation in its preparation was entrusted to Technical Committee GEL/107, Process management for avionics, which has the responsibility
4、 to: A list of organizations represented on this committee can be obtained on request to its secretary.Cross-referencesThe British Standards which implement international or European publications referred to in this document may be found in the BSI Catalogue under the section entitled “International
5、 Standards Correspondence Index”, or by using the “Search” facility of the BSI Electronic Catalogue or of British Standards Online.This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compliance with a British Sta
6、ndard does not of itself confer immunity from legal obligations. aid enquirers to understand the text; present to the responsible international/European committee any enquiries on the interpretation, or proposals for change, and keep UK interests informed; monitor related international and European
7、developments and promulgate them in the UK.Summary of pagesThis document comprises a front cover, an inside front cover, the EN title page, pages 2 to 32, an inside back cover and a back cover.The BSI copyright notice displayed in this document indicates when the document was last issued.Amendments
8、issued since publicationAmd. No. Date CommentsLicensed Copy: Wang Bin, na, Mon Mar 13 07:18:31 GMT 2006, Uncontrolled Copy, (c) BSIEUROPEAN STANDARD EN 50389 NORME EUROPENNE EUROPISCHE NORM September 2005 CENELEC European Committee for Electrotechnical Standardization Comit Europen de Normalisation
9、Electrotechnique Europisches Komitee fr Elektrotechnische Normung Central Secretariat: rue de Stassart 35, B - 1050 Brussels 2005 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members. Ref. No. EN 50389:2005 E ICS 49.060 English version Space produc
10、t assurance Wire-wrapping of high-reliability electrical connections Conformit des produits spaciaux - Connexion par enroulement des connexions lectriques de haute fiabilit Raumfahrt-Produktsicherung Ltfreie elektrische Drahtverbindungen hoher Zuverlssigkeit This European Standard was approved by CE
11、NELEC on 2005-08-01. CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national stand
12、ards may be obtained on application to the Central Secretariat or to any CENELEC member. This European Standard exists in two official versions (English, German). A version in any other language made by translation under the responsibility of a CENELEC member into its own language and notified to th
13、e Central Secretariat has the same status as the official versions. CENELEC members are the national electrotechnical committees of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Ne
14、therlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. Licensed Copy: Wang Bin, na, Mon Mar 13 07:18:31 GMT 2006, Uncontrolled Copy, (c) BSIEN 50389:2005 - 2 - Foreword This European Standard was prepared by the Technical Committee CENELEC TC 107X, Pr
15、ocess management for avionics (former CENELEC BTTF 91-3). The text of the draft was submitted to the formal vote and was approved by CENELEC as EN 50389 on 2005-08-01. The following dates were fixed: latest date by which the EN has to be implemented at national level by publication of an identical n
16、ational standard or by endorsement (dop) 2006-08-01 latest date by which the national standards conflicting with the EN have to be withdrawn (dow) 2008-08-01 It is based on a previous version 1)originally prepared by the ECSS product assurance working group, reviewed by the ECSS Technical Panel and
17、approved by the ECSS Steering Board. The European Cooperation for Space Standardization (ECSS) is a cooperative effort of the European Space Agency, National Space Agencies and European industry associations for the purpose of developing and maintaining common standards. This European Standard is on
18、e of a series of space standards intended to be applied together for the management, engineering and product assurance in space projects and applications. Requirements in this European Standard are defined in terms of what shall be accomplished, rather than in terms of how to organize and perform th
19、e necessary work. This allows existing organizational structures and methods to be applied where they are effective, and for the structures and methods to evolve as necessary without rewriting the standards. The formulation of this European Standard takes into account the existing EN ISO 9000 family
20、 of documents. 1)ECSS-Q-70-30A. Licensed Copy: Wang Bin, na, Mon Mar 13 07:18:31 GMT 2006, Uncontrolled Copy, (c) BSI- 3 - EN 50389:2005 Contents Introduction.5 1 Scope.5 2 Normative references .6 3 Terms, definitions and abbreviated terms .7 3.1 Terms and definitions 7 3.2 Abbreviated terms .8 4 Pr
21、eparatory conditions8 4.1 Hazards, health and safety precautions.8 4.2 Facility cleanliness 8 4.3 Environmental conditions 8 4.4 Lighting requirements9 4.5 Configuration of process/workpiece.9 4.6 Cleaning9 4.7 Tools and equipment .9 4.7.1 General.9 4.7.2 Cutting tool .9 4.7.3 Insulation strippers9
22、4.7.4 Wire-wrapping tools 10 4.7.5 Unwrapping tools 11 4.8 Tool calibration12 4.9 Wire-wrap process certification12 4.10 Test monitoring equipment 13 5 Materials selection .13 5.1 Wire 13 5.1.1 General.13 5.1.2 Conductor .13 5.1.3 Wire insulation 13 5.2 Terminal post 14 5.3 Wire to terminal post com
23、binations16 6 Wire-wrap operation .16 6.1 Preparation for wire-wrapping16 6.2 Process.16 6.3 Wire-wrap criteria18 6.3.1 Usage of wrap levels.18 6.3.2 Number of turns on terminal post 19 6.3.3 Positioning and regularity of wrap connection19 6.3.4 Wire routing 19 6.3.5 Rework19 6.3.6 Wire-wrap and sol
24、der connections onto the same terminal post.20 7 Test methods .20 7.1 General .20 7.2 Workmanship 20 7.3 Stripping force.20 7.4 Unwrapping test 22 7.5 Connection resistance.22 7.6 Gas-tightness test .23 Licensed Copy: Wang Bin, na, Mon Mar 13 07:18:31 GMT 2006, Uncontrolled Copy, (c) BSIEN 50389:200
25、5 - 4 - 7.7 Metallography24 7.8 Records of tests 24 8 Acceptance criteria.25 8.1 Visual inspection .25 8.2 Performance tests .26 8.2.1 General.26 8.2.2 Stripping force test26 8.2.3 Unwrapping test 27 8.2.4 Connection resistance test 27 8.2.5 Gas-tightness test .27 8.2.6 Metallography .27 9 Quality a
26、ssurance.27 9.1 General .27 9.2 Data 27 9.3 Nonconformance .27 9.4 Calibration.27 9.5 Traceability .27 9.6 Workmanship standards 29 9.7 Operator and inspector training and certification29 9.8 Inspections29 9.8.1 Visual inspection.29 9.8.2 Process control .29 10 Verification .30 10.1 General .30 10.2
27、 Temperature cycling30 10.3 Vibration30 Annex A (informative) Daily process control sheet for test samples.31 Bibliography32 Figure 1 Single wire-wrapped connection to square terminal and reference corner .6 Figure 2 Examples of approved wire-wrapping tools .11 Figure 3 Hand unwrapping tools .11 Fig
28、ure 4 Minimum wrapping length on terminal post for each wire gauge15 Figure 5 Terminal post dimensions over minimum wrapping length for each terminal size .15 Figure 6 Wire-wrap connection process 17 Figure 7 Position and regularity of wrap connection18 Figure 8 Stripping force test fixture.21 Figur
29、e 9 Connection resistance test22 Figure 10 Gas-tightness test result .23 Figure 11 Typical cross-section of wire-wrap (64).24 Figure 12 Wire-wrap rejection criteria which require reworking of the connection26 Figure 13 Guide to quality assurance during wire-wrapping 28 Table 1 Wire size to terminal
30、post combinations .16 Table 2 Minimum number of wire turns on terminal post .19 Table 3 Minimum stripping force.21 Table 4 Test current for connection resistance .23 Licensed Copy: Wang Bin, na, Mon Mar 13 07:18:31 GMT 2006, Uncontrolled Copy, (c) BSI- 5 - EN 50389:2005 Introduction This standard de
31、fines the requirements and quality assurance provisions for the manufacture of high-reliability wire-wrapped connections made with round single-strand silver-plated wire onto appropriately designed gold-plated terminals. Equipment design requirements, such as terminal spacing and terminal mounting a
32、re not included in this standard. This standard deals with the mechanical and electrical stability of wire-wrapped connections operating under high vacuum, thermal cycling and vibration conditions imposed by space flight. 1 Scope This standard specifies the methods for preparing and assembling the p
33、arts to be joined by wire wrapping, and the selection, calibration, use and certification of the wire wrapping tools. The required wire-wrapped connections are illustrated in Figure 1. This type of connection is similar to “Class A preferred” or “modified” connection detailed in MIL-STD-1130, and NA
34、SA NHB 5300.4(3H). Only tested and qualified wire-wrapped connections are covered by this standard, which lists four wire sizes from 24 AWG to 30 AWG, and three terminal post sizes up to 1,78 mm maximum diagonal. The use of thicker wire and larger terminals are not advised. Thicker wire than 24 AWG
35、is generally multistranded and terminated by soldering (see ECSS-Q-70-08) or by crimping (see ECSS-Q-70-26). Training and certification requirements for operators and inspectors are defined in 9.7 and in EN 13291-1. Licensed Copy: Wang Bin, na, Mon Mar 13 07:18:31 GMT 2006, Uncontrolled Copy, (c) BS
36、IEN 50389:2005 - 6 - Terminal postEnd tailUninsulated wire turnsInsulated wireReference corner(and at 1 below)1231234Shows either 3 or 4 corners of contact of insulation minimum turn of insulated wireFigure 1 Single wire-wrapped connection to square terminal and reference corner 2 Normative referenc
37、es 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 (including any amendments) applies. EN 13291-1 Space product assurance - General r
38、equirements - Part 1: Policy and principles EN 13291-2Space product assurance General requirements - Part 2: Quality assurance EN 13701Space systems - Glossary of terms EN 14097 Space product assurance - Non conformance control system Licensed Copy: Wang Bin, na, Mon Mar 13 07:18:31 GMT 2006, Uncont
39、rolled Copy, (c) BSI- 7 - EN 50389:2005 ECSS-Q-70-02 Space product assurance - Thermal vacuum outgassing test for the screening of space materials ESA/SCC No. 3903 Solid wires, electrical 350 V, for wire wrapping 3 Terms, definitions and abbreviated terms 3.1 Terms and definitions For the purposes o
40、f this European Standard, the terms and definitions given in EN 13701 and the following apply. 3.1.1 wire-wrapped connection this connection consists of a helix of continuous, solid, uninsulated wire tightly wrapped around the terminal post to produce a mechanically and electrically stable connectio
41、n NOTE The number of turns required depends on the gauge of wire used. All completed wraps have an additional minimum of 3/4 turn of the insulated wire that is in contact with at least three corners of the terminal post (see Figure 1). 3.1.2 terminal post post of square or rectangular section onto w
42、hich the interconnection wire is wrapped 3.1.3 a turn of wire this consists of one complete single helical ring of wire wrapped 360 around the terminal post, touching all four corners of the post NOTE For the purpose of counting turns, the number of times the wrapped wire passes and intercepts the r
43、eference edge of the terminal post after the first intercept of uninsulated wire and terminal post, constitutes the number of turns of uninsulated wire in the connection. 3.1.4 reference corner corner of the terminal post at which the first turn of uninsulated wire contacts, and from which the numbe
44、r of turns of the wrapped wire are counted 3.1.5 end tail end of the last turn of wire on the terminal post which may extend in a tangential direction instead of resting against the post 3.1.6 gas-tight area contact area between the terminal post and wire which excludes gas fumes Licensed Copy: Wang
45、 Bin, na, Mon Mar 13 07:18:31 GMT 2006, Uncontrolled Copy, (c) BSIEN 50389:2005 - 8 - 3.2 Abbreviated terms The following abbreviated terms are defined and used within this European Standard: AWG American wire gauge; ECSS European Cooperation for Space Standardization; ETFE ethylene-tetrafluorethyle
46、ne; PTFE polytetrafluorethylene; PVDF polyvinylidene fluoride; PFA perfluoroalkoxy; RH relative humidity. 4 Preparatory conditions 4.1 Hazards, health and safety precautions Particular attention shall be paid to health and safety precautions. A safety checklist is produced below: a) hazards to perso
47、nnel, equipment and materials shall be controlled and reduced to a minimum; b) components, tools and controls shall be so located that personnel are not exposed to hazards such as electric shock, cutting edges, sharp points or toxic atmospheres; c) pneumatic air-powered wire-wrapping tools shall be
48、connected to a regulated, lubricated and filtered air supply, and disconnected when not in use. 4.2 Facility cleanliness a) Unless classified as a cleanroom, the areas in which wire-wrapping is carried out shall be maintained in a neat orderly fashion, with no loose material (such as dirt, dust, oil
49、s or clipped wires) that can cause contamination of the wire-wrapped connection. Furniture shall be kept to a minimum in the work areas and be arranged to allow easy and thorough cleaning of the floor. b) Working surfaces shall be covered with an easily cleaned hard top, or have a replaceable surface of clean, noncorrosive silicone-free paper. c) Tools used in the wire-wrapping operation shall be clean. Excess lubricants shall be removed before wire-wrapping starts. d) Before assembly, wire and terminal posts shall be
