1、“. !MIL-HDBK-L76 hl W 9777770 00053q7 1 m A- 3 3- 2-3 MIL-HDBK-176 17 MAY 1972 MILITARY STANDARDIZATION HANDBOOK GUIDANCE FOR FLEXIBLE FLAT MULTICONDUCTOR CABLE (FLAT CONDUCTORS) / T. . Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-DEPARTMENT OF
2、 DEFENSE WASHINGTON 25, D. C. MIL-HDBK- 176 Guidance for Flexible Flat Multiconductor Cable 17 Wes 1972 1. This standardization handbook was developed by the Department of Defense with the assistance of the National Aeronautics and Space Administration in accordance with established procedure. 2, Th
3、is publication was approved on 17 1972 for printing and inclusion in the military standardization handbook series. 3. This document provides basic and fundamental information on FCC electrical inter- connecting harnesses and manufacturing practices, It will provide valuable information and guidance
4、to personnel concerned with the preparation of specifications and the procurement of FCC electrical interconnecting harnesses. The handbook is not intended to be referenced in purchase specifications except for informational purposes, nor shall it supersede any specifi- cation requirements. 4. Every
5、 effort has been made to reflect the latest information on FCC electrical inter- connecting harnesses and manufacturing practices. It is the intent to review this handbook periodically to insure its completeness and currency, Users of this document are encouraged to report any errors discovered and
6、any recommendations for changes or inclusions to U. S. Army Electronics Command, Attn: AMSEL-RD-ZS , Ft. Monmouth, N. J. 07703. ii 7 Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-FOREWORD The use of flat-conductor cable (FCC) offers technologica
7、l and economical advantages. When the program managers and personnel responsible for the system design have properly evaluated the major FCC advantages of cost, space, and weight reductions, with increased system performance and reliability, the general use of FCC for both military and commercial pr
8、o- grams will be assured. A number of independent surveys made by separate agencies have indicated that the use of FCC for interconnecting harnesses in all new design of .aircraft, missiles, and ground equipment will be 40-55 percent by 1975. FCC has seen limited use on many successful programs for
9、a number of years. However, it is expected that, with its acceptance and general use, many new application techniques and hardware configurations will be developed. New FCC technology has been reached. Even though the technology is still young, and much more is required for future development hardwa
10、re and system application, the ultimate success of the system is assured. This handbook is prepared for use by engineers, designers and technicians and is intended to serve as a text. The test presents pertinent information for hardware selecting, design, manufacture and quality control necessary fo
11、r FCC interconnecting harness application. r- Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-L76 bL m 7777970 0005350 L m CONTENTS c 1.1General 1 1.2 Purpose 1 1.3 History . 1 1.4 FCC System Advantages . 4 1.4.1 Weight Saving 4 1.4.2 Spa
12、ce Saving 4 1.4.3 Costsaving . 4 1.4.4 Increased Thermal Capacity 8 1.4.5 Improved System Performance . 8 1.4.6 Increased Reliability 8 1.5 Present Status of FCC 8 1.5.1 Specifications 8 1.5.2 Available Hardware 8 1.5.3 System Studies . 9 1.6 Predicted Future Use . 9 1.7 Report Format 11 1.8 Trade N
13、ames . 11 SECTIONII . FCC HARDWARE 12 2.1 Introduction . 12 2.2 Cable 12 2.2.1 General Description 12 2.2.2 Insflation Materials 14 2.2.3 Conductors . 14 2.2.5 Shielded Cable . 19 2.2.6 Power Cable 21 2.2.4 Nonshielded Cable ; 14 2.3 Connectors 24 2.3.1 Introduction . 24 2.3.2 Conductor-Contact Conn
14、ectors (per MIL-C-55544) 24 2.3.3 Pin-and-Socket (per MIL.C.55544) . 29 2.3.4 Other FCC Connectors . 36 V Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-L76 61 W 7797770 0005353 3 MIL-HDBK- 176 17 1972 CONTENTS (Continued) 2.5 clamp S 45
15、 2.5.1 Introduction 45 2.5.2 Designmals 45 2.5.3 Clamps for Severe Environmental Conditions . 48 2.5.4 Clamps for Noncritical Application 48 2.5.5 Shop-Aid Clamp Support 48 2.6 Supports . 58 2.6.1 Introduction 58 2.6.2 Use of Existing Structure . 58 2.6.3 Added Supports . . 58 2.7 Adhesives and Tape
16、s . 58 2.7.1 Adhesives . 58 2.7.2 Tapes 61 3.1.1 Purpose . 62 3.1.2 Comparison of FCC to RWC Systems . 62 3.1.3 oncusions 67 3.2 FCC Application . 69 3.2.1 Program Considerations 69 3.2.2 Network System Requirements . 69 3.2.3 Design Considerations . 69 3.2.4 FCC Power Cables . 134 3.2. 5 Harness De
17、sign 138 3.2.6 FCC Harness Installation . 146 3.2.7 OtherDrawings 151 3.2.8 Special Applications 155 3.2.9 Mechanized Design . 166 3.2.10 EMC Theory 172 Vi Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-4 MIL-HDBK-L76 bL r 7797970 0005352 5 I- MI
18、L-HDBK-176 17 “V 1972 CONTENTS (Continued) 4.2.1 Production . 204 4.2.2 Temporary . 208 4.3 Distribution Units 208 I 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8 4.3.1 System Advantages . 208 4.3.2 Design Objectives . 211 4.3.3 Configurations . 211 4.4 Conclusion . 213 SECTIONV . RELIABILITY . i
19、217 5.1 Introduction 217 5.2 Cable . 217 5.3 Connectors 218 5.4 Harness Assemblies . 218 5.5 Harness Installations . 219 5.6 Heat Dissipation . 219 5.7 System Performance . 219 5.8 Conclusions 220 SECTION VI. MANUFACTURING AND INSTALLATION TECHNIQUES 221 6.1 General 221 6.2 Mock-up Installation . 22
20、1 6.2.1 Materials 221 62.2 Installation Aids 221 6.2.3 General Procedures 221 6.3 Detail Manufacturing . 224 MaterialHandling 224 Cable Shearing . 224 Cable Stripping . 224 Conductor and Shield Plating . 236 FCC Plug Assembly 244 Folding Flat Cable 252 FCC to RWC Transition 256 Procedure for Term.in
21、ation FCC to Ground Lugs . 260 6.4 Assembly and Installation of FCC Harnesses 262 6.4.1 FCC Cable Assembly . 262 6.4.2 FCC Harness Installation . 262 6.4.3 Installation of Supports and Clamps . 262 vii Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,
22、-,-MIL-HDBK-L76 bL G 7777970 0005353 7 m i- MIL-HDBK- 176 17 W 1972 CONTENTS (Continued) Page 6.5 Summary . 265 SECTION VD . QUALITY ASSURANCE . INSPECTION AND TEST PROCEDURES * . * . * 267 7.1 Introduction . 267 7.2 Inspection and Test Plan Outline . -. . 267 7.3 In-Process Quality Control Flow Cha
23、rts 267 7.4 Receiving Inspection . 288 7.4.1 Cable Inspection and Test . 288 7.4.2 Receiving Inspection Premolded Plugs (Shielded and Unshielded) 299 7.4.3 Receiving Inspection of Related Plug Materials 300 7.4.4 Molding Compounds. Potting Compounds. and Adhesives Control 300 7.4.5 Receiving Inspect
24、ion . Receptacles 301 7.4.6 Receiving and Inspection of Clamps and Supports . 302 7.5 In-Process Inspection and Test of Cable Preparation for Termination. 302 7.5.1 Cable-Shearing Inspection 302 7.5.2 Cable-Stripping Inspection 302 7.5.3 Conductor and Shield Plating 305 7.6 Inspection and Test of Ca
25、ble Terminations . 307 7.6.1 Inspection of Molded-On Plug Assembly. Rectangular 307 7.6.2 Inspection of Molded-On Plug Assembly. (Cylindrical) 308 7.6.3 Inspection and Test of Premolded Plug Assembly (Unshielded) . 309 7.6.4 Special Terminations . 310 7.6.5 Inspection of FCC to Round-Wire Transition
26、s 310 7.7 Final Inspection and Test of Cable Assembly 311 7.7.1 Visual/Mechanical . 311 7.7.2 Electrical Testing . 311 7.8 Installation of FCC. Inspection and Test Requirements . 311 7.8.1 Installation of Supports and Clamps . 312 7.8.2 FCC Harness - Preparation for Installation . 312 7.8.3 Routing
27、Cable Bundles . 312 TABLES 1- 1 . Cost Comparison . FCC Versus RWC Systems 4 2- 1 . Detailed Characteristics of Various Insulations . 15 2- 2 . Mn-C-55543 Cable Configuration 16 2- 3 . MIL-C-55543 FCC Dimensional Data . 17 2- 4 . Adhesives for Flat-Cable Installation . 60 viii Provided by IHS Not fo
28、r Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-L76 bL 7777770 0005359 7 MIL-HDBK- 176 17 May 1972 TABLES (Continued) Page 3- 1. Cost Comparison . FCC versus RWC Systems 65 3- 2 . FCC Cable Selection Chart . Conductor Size and Resistance . 70 3- 3 . Configurat
29、ion Correction Factors for Current Ratings 77 3- 4 . Capacitance Values in pF/ft for Mylar Insulated Flat Cable (E = 2.5) 78 3- 5 . Capacitance Values in pF/ft for H-Film/FEP Insulated Flat Cable (c = 2.9-3.1) . 79 3- 6 . Capacitance Values for Mylar (4 = 2.5) and H-Film/FEP ( = 2.9 . 3.1) Insulated
30、 Flat Cable 80 (C=2.9-3.1). 81 3- 8 . Termination Impedance Coupling Factor . 96 3- 9 . Frequency/Time Coupling Factor . 97 3- 11. Amplitude Susceptibility/Interference Factor . 98 3- 12 . ResolutiodAccuracy Susceptibility Factor 98 3-13 . FCC Power Cable Conductor Cross Sections . 136 3- 7 . Capaci
31、tance Values in pF for a Double-Shielded H-Film/FEP Cable 3-10 . Length Coupling Factor . ; 97 3-14 . Typical Interconnecting Requirements 139 3-15 . FCC Cable Selector Chart . 142 3-16 . FCC Connector Selector Chart 142 3-17 . Cable Selection and Zoning - Harness 1-1 . 147 6- 1. Solutions for Remov
32、ing Mylar . 224 6- 2. Maskants 227 6- 3 . Stripping Solutions for Polyimide Insulation Materials 229 7- 1 . Inspection and Test Outline for Flat Cable Assembly Manufacturing . 268 Figure ILLUSTRATIONS Page aft-skirtmockup 2 mockup 3 1- 3 . Weight-saving chart - FCC versus RWC 3 1- 1 . FCC versus RWC
33、 comparison, 180-degree section of Saturn S-WB 1- 2 . FCC versus RWC comparison, 60-degree section, Saturn S-WB Provided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK-176 17 m 1972 ILLUSTRATIONS (Continued) Figure Page 1- 4 . Space saving . FCC
34、versus RWC . 5 1- 5 . Mounting and handling area configurations 6 1- 6 . Mounting and handling area . FCC versus RWC connectors . 7 1- 7 . Cable cost saving . FCC versus RWC . 9 1- 8 . FCC harness installation for aircraft application evaluation (MDC) . 10 2- 1 . FCC cross-sections for various manuf
35、acturing methods . 13 2- 2. FCC elongation versus tensile load 18 2- 3 . Shielded FCC with offset edge conductors . 20 2- 4 . Shielded FCC with non-offset edge conductors 20 2- 5 . Shielded-cable preparation for plug termination . 22 2- 6 . FCC power.cable configuration . ,. . 23 2- 7 . Multiple cab
36、le terminations in one layer . 25 . 2- 8 . FCC power-cable termination 25 2- 9 . MIL-C-55544/5 Molded-on rectangular plug . 26 O . 25-inch-wide cable . 27 2-10 . MIL-C-55544/9 Molded-on cylindrical plug assembly. . 1 2.11 . 2.12 . 2.13 . 2.14 . 2- 15 . 2.16 . 2.17 . 2.18 . MIL-C-55544/9 Molded-on cy
37、lindrical plug assembly. 0.5-inch-wide cable 28 MIL-C-55544/5 Premolded rectrrngular plug 30 FCC to FCC receptacle. rectangular . 31 FCC to RWC receptacle. rectangular . 32 MIL-C-55544116 FCC to FCC receptacle. cylindrical 33 MIL-C-55544/14 FCC to RWC receptacle. cylindrical 34 Pin-and-socket connec
38、tors (Picatinny Arsenal) 35 Multilayer connector. 16-gwe contacts (ELCO) . 35 2.19 . Multilayer connector prototype for Poseidon . 37 2.20 . Multilayer connector cross-section for Poseidon . 37 2.21 . MARK II Micro Dot high-denslty connector 38 2.22 . MMD high-density connector (Micro Dot) . 38 Prov
39、ided by IHS Not for Resale No reproduction or networking permitted without license from IHS -,-,-MIL-HDBK- 176 17 My 1972 ILLUSTRATIONS (Continued) Figure page 2.23 . 50-Mil center multilayer prototype 39 2.24 . 218 Flex-1 series connector (Amphenol) . 39 2.25 . Crimp contact connector (Amp) 39 2.26
40、. Multilayer connector (ELCO) . 41 2.27 . Retractable cable assembly (ACI) . 41 2.28 . Harness Aesembly (ACI) 42 2.29. Harness assembly (Methode Electronics) . 42 2.30 . Shielded assembly (Ansley West) . 43 2.31 . Gyro harness assembly (Ansley West) 43 2.32 . Harness assembly (Rogers Corp.). 44 2.33
41、 . Harness assembly (ECS) 44 2.34 . FCC toRWC transition 46 2.35 . 2.36 . 2.37 . 2.38 . 2.39 . 2.40 . 2.41 . 2.42 . 2.43 . 2.44 . 2.45 . 2.46 . 2.47 . PC-board distribution box . 46 Jumper wire distribution box . 47 Termi-point distributor 47 Lap clamp assembly. single. 100C . 49 Lap clamp assembly.
42、 double. 100C . 50 Lap clamp assembly. triple. 100C . 51 Lap clamps and support, curved surface. 100C . 52 . Tubular clamps with nylon fasteners. 100C . 52 Metal noncushioned clamps. 200C 53 Metal noncushioned clamp. right-angle tubular. 200.C 53 Tubular clamps with screw fasteners. 100C . 54 Metal
43、noncushioned clamp. right-angle sheet metal, 200C . 54 Metal-cushioned clamp. 200C 55 2.48 . Metal-cushioned clamp. double grip. 200C . 56 2.49 . Metal-cushioned clamps for angle fold, 200C 56 2.50 . Plastic clamps and fasteners 57 . xi Provided by IHS Not for Resale No reproduction or networking pe
44、rmitted without license from IHS -,-,-ILLUSTRATIONS (Continued) Figure Page 2.51 . Shop aid cable support . 57 2.52 . Typical FCC support installations 59 3- 1 . Nonshielded cable weight comparison . 63 3- 2 . Nonshielded cable space comparison . 63 3- 3 . FCC to round connectors . with pin-assignme
45、nt changes . 68 3- 4 . 3- 5 . 3- 6 . 3- 7 . 3- 8 . 3- 9 . 3- 10 . 3.11 . 3.12 . 3- 13 . Flat to round connectors . without pin-assignment changes (Ansley West) 68 FCC cross-sections . equivalent AWG 20 through 30 . 72 Resistance correction factor . ,. . 72 Surface cross-section comparison . FCC to R
46、WC 73 (25 conductors) . 73 (25 conductors) . 73 Current versus temperature rise in hottest conductor in air Current versus temperature rise in hottest conductor in vacuum y;urimum current versus temperature rise in hottest conductor in air . 74 Maximum current versus temperature rise in hottest cond
47、uctor in vacuum . 74 Distributed capacitance between conductors . 75 Inner conductor capacitance configurations for unshielded flat cable 75 3.14 . Double-shielded cable capacitance configurations 82 3.15 . 3- 16 . 3.17 . 3- 18. 3.19 . 3.20 . 3.21 . 3.22 . 3.23 . 3.24 . Conductor-to-shield capacitan
48、ce for double-shielded FCC 83 Conductor-to-shield capacitance for double-shielded FCC 84 Conductor-to-shield capacitance for double-shielded FCC 85 Conductor-to-shield capacitance foi double-shielded FCC 86 Conductor-to-shield fringe capacitance for double-shielded FCC 87 Components d inductance in
49、a flat cable running in a straight line . 89 Total inductance of edge-to-edge conductors in a return circuit . 89 Total inductance d.over-and-under conductors in a return circuit 91 line circuit, dielectric constant = 2.5 91 line circuit. dielectric canstant = 2.9 92 Characteristic impedance of edge-to-edge conductors in a transmission- Characteristic impedance d ed
