ARMY MIL-E-45782 C NOTICE 1-1998 ELECTRICAL WIRING PROCEDURES FOR《电线制造程序》.pdf

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1、INCH-POUNDMIL-E-45782CMILITARY SPECIFICATIONELECTRICAL WIRING, PROCEDURES27 August 1993SUPERSEDINGMILE-45782B28 December 1967FORThis specification is approved for use by allDepartments and Agencies of the Department ofDefense.1. SCOPE.1.1 Scope. This specification covers the fabrication andterminati

2、on of shielded electrical harness and cable assemblies,and the wiring of electrical and electronic circuits ofsubassemblies used in missile systems.1.2 Classification. Shield termination and securing ofharnesses, cables, and wire bundles are classified using thefollowing types, classes, and methods,

3、 as specified. In the eventthat a class or method is not applicable to a particular assembly,that portion of the classification should be omitted from theordering data (see 6.2).Beneficial comments (recommendations, additions, cieletions) anrjany pertinent data which may be of use in improving this

4、documentshould be addressed to: Commander, U.S. Army Missile Command,ATTN: AMSMI-RD-SE-TD-ST, Redstone Arsenalr AL 35898-5270 byusing the Standardization Document Improvement Proposal (DD Form1426) appearing at the end of this document or by letter.AMSC N/A FSC 1430DISTRIQ.UTION STATEMENT A. Approve

5、d for public release;distribut”ion is unlimited.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-E-45782C1.2.1 Types. Types of shield terminations are as follows:Type I without ferrulesType II with one-piece ferrules (not for use innew design, see

6、 3.8).Type III - with two-piece ferrules1.2.2 Class. Classes of shield terminations are as follows:Class 1 - ungroundedClass 2. grounded1.2.3 Terminating method. Methods used for shieldsterminated with ferrules are as follows (see 3.3.3.2 and 3.3.3.3):Method A - one-piece ferruleMethod B - twopiece

7、ferruleMethod - two-piece ferruleMethod D - two-piece ferruleMethod E two-piece ferrule combed shield)Method F - two-piece ferrule,(see 3.8).(braided shield)(combed shield)(folded, combed shield)(insulated, folded,multiple-shieldedcondctor, doublefolded- shieldMethod G - two-piece ferrule, multiple-

8、shieldedconductors, single-folded shield.1.2.4 Securing method. Methods to be used when cables,harnesses, or wire bundles are to be secured are as follows (see3.3.8):Method a - double-lock stitchMethod b - single-lock stitchMethod c - lacing tiesMethod d - harness straps2. APPLICABLE DOCUMENTS2.1 Go

9、vernment documents.2.1.1 Specifications, standards, and handbooks. Thefollowing specifications, standards, and handbooks form a part ofthis document to the extent specified herein. Unless otherwisespecified, the issues of these documents are those listed in theissue o.fthe Department of Defense Inde

10、x of Specifications andStandards (DODISS) and supplement “thereto, cited in thesolicitation (see 6.2).2Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-E-45782CSPECIFICATIONSFEDERALO-F-506P-D-680QQ-B-575QQ-S-571MILITARYMIL-C-17MIL-I-631.MIL-T-713M

11、IL-Y1140MIL-I3190MIL-I-3190/6 -MIL-C5015MIL-W-5086MIL-W-5088MIL-C-7078MILI7444.Flux, Soldering; Paste andLiquidDry Cleaning and DegreasingSolventBraid, Wire (Copper, Tin-Coated,or Silver Coated, Tubular, orFlat)Solder, Tin Alloy, Tin-LeadAlloy, and Lead AlloyCables, Radio Frequency,Flexible and Semi

12、rigid, GeneralSpecification forInsulation, Electrical,Synthetic-Resin Composition,NonrigidTwine, Fibrous: Impregnated,Lacing and TyingYarn, Cord, Sleeving, Cloth, andTapeGlassInsulation Sleeving, Electrical,Flexible, Coated, GeneralSpecification forInsulation Sleeving, Electrical,Flexible, Coated, C

13、lass 200,Type D, Category CConnectors, Electrical, CircularThreaded, AN Type, GeneralSpecification forWire, Electric, PolyvinylChloride Insulated, Copper orCopper AlloyWiringrAerospace VehicleCable, Electric, AerospaceVehicle, General SpecificationforInsulation Sleeving, Electrical,FlexibleProvided

14、by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MILE-45782CMIL-T-7928MILT792815 -MIL-C-8603MIL-F-14256MIL-w-16878MIL-F-21608MIL-I-22076MILI-22129MIL-c22520/5 MIL-W-22759/l MILw-22759/2 -MIL-I-23053MILS-23190MIL-C26482Terminals, Lug: Splices,Conductor: Crimp S

15、tyle, Copper,General Specification forTerminals, Lug and Splices,Conductor, Crimp Style, Splice,Electric, (Permanent, Type II,Class 1) for 105”C TotalConductor TemperatureClamps, Tube Support, Loop TypeFlux, Soldering, Liquid (RosinBase)Wire, Electrical, Insulated,Specification forFerrule, Shield Te

16、rminating,Crimp StyleInsulation Tubing, Electrical,Nonrigid, Vinyl, Very LowTemperature GradeInsulation Tubing, Electrical,Polytetrafluoroethylene Resin,NonrigidCrimping Tools, Terminal, Hand,Wire Terminationr Large forCoaxial, Shielded Contacts andFerrules, Terminal Lugs, Spliceand End CapsWirer El

17、ectric, Fluoropolymer-Insulated, TFE and TFE-Coated-Glass, SilverCoated CopperConductor, 600-VoltWire, Electric, Fluoropolymer-Insulated, TFE and TFECoated-Glassr NickelCoated CopperConductor; 600-VoltInsulation Sleeving, Electrical,Heat Shrinkable, GeneralSpecification forStrap, Clamps, and Mountin

18、gHardware, Plastic and Metal forCable Harness Tying and SupportConnectors, Electrical,(Circular, Miniature, QuickDisconnect, EnvironmentResisting), Receptacles andPlugs, General Specification for4Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-E-

19、45782CMIL-C-26500MIL-C-27500MIL-C-45224MIL-W-81044MIL-C-83723MIL-C-85049/lMIL-C-85049/2MIL-C-85049/41MIL-C-85049/42.*.Connectors, General Purpose,Electrical, Miniature, Circular,Environmental Resisting, GeneralSpecification forCable, Power, Electrical andCable Special Purpose,Electrical Shielded and

20、Unshielded, GeneralSpecification forCable and Harness Assemblies,Electrical, Missile System:General Specification forWire, Electric, Cross LinkedPolyalkene, Crosslinked Alkane-Imide Polymer, or PolyaryleneInsulated, Copper or CopperAlloyConnectors, Electrical,(Circular, EnvironmentResisting), Recept

21、acles andPlugs, General Specification forConnector Accessories,Electrical, Backshell,Environmental, Cable Sealing,Straight, Grounding (WithoutStrain Relief), Category lC (forMIL-C-5015 Solder Type, V Threadof MS31OX Classes A, B, C or KConnectors)Connector Accessories,Electrical, Backshell,Environme

22、ntal, Cable SealingStraight, Category lC (for MIL-C-5015 Solder Type, V Thread ofMS31OX Classes A, B, C or KConnectors)Connector Accessories,Electrical, Nonenvironmental,Strain Relief, Straight,Category 4C (For MIL-C5015Solder Type, V Thread of MS31OXClasses A, B, C or K Connectors)Connector Accesso

23、ries,Electrical, Nonenvironmental,Strain Relief, Straight,Category 4A (for MIL-C-5015Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-E-45782C.STANDARDSMILITARYMILSTD-130MILSTD-202MIL-STD-454MIL-STD-461MIL-STD-462MIL-STD-2000MS3367MS17776MS20659MS

24、25036Solder Type, V Thread of MS31OXClasses A, B, C or K Connectors)Identification Marking of USMilitary PropertyTest Methods for Electronic andElectrical Component PartsStandard General Requirementsfor Electronic EquipmentElectromagnetic Emission andSusceptibility Requirements forthe Control of Ele

25、ctromagneticInterferenceElectromagnetic InterferenceCharacteristics, Measurement ofStandard Requirements forSoldered Electrical andElectronic AssembliesStrap, Tiedown, ElectricalComponents, Adjustable Self-Clinching, Plastic, Type I Class1Crimping Tool, Terminal, Hand,Lug Terminal and External Power

26、Plug Socket Contacts, 22-10CapacityTerminal, Lug, Crimp Style,Copper, Uninsulated, RingTongue, Type I, Class 1 for175C Total ConductorTemperatureTerminal, Lug, Crimp Style,Copper, Insulated, Ring Tongue,Bell-Mouthed, Type II, Class 1,(For 105”C Total ConductorTemperature).6Provided by IHSNot for Res

27、aleNo reproduction or networking permitted without license from IHS-,-,-MIL-E-45782CMS27470 Connector, Receptacle,Electrical, Jam Nut Mounting,Solder Type, Hermetic Seal,Series IMS27471 Connector, Receptacle,Electrical, Solder Mounting,Solder Type, Hermetic Seal,Series IMS90387 Tool, Hand Adjustable

28、 forPlastic and Metal Tiedown StrapsMS90485 Dies, Crimping Tool, for Usewith MS20659 Uninsulated WireTerminals and External PowerPlug Socket Contacts (for WireSizes 8 Through 4/0)(Unless otherwise indicated, copies of the federal andmilitary specifications, standards, and handbooks are availablefrom

29、 the Standardization Documents Order Desk, Bldg. 4D, 700Robbins Ave., Philadelphia, PA 19111-5094.)-2.2 Non-Government publications. The following documentsform a part of this document to the extent specified herein.Unless otherwise specified, the issues of the documents which areDoD adopted are tho

30、se listed in the issue of the DODISS cited inthe solicitation. Unless otherwise specified, the issues ofdocuments not listed in the DODISS ar the issuescited in the solicitation (see 6.2) .SOCIETY OF AUTOMOTIVE ENGINEERSAMS-3815 - Braid, Flat, Nylon,of the documentsElectrical Tvina,Synthetic Rubb;r

31、Coated -.(Application for copies should be addressed to the Society ofAutomotive Engineers, Inc., 400 Commonwealth Dr., Warrendale, PA15096.)(Non-Government standards and other publications are normallyavailable from the organizations that prepare or distribute thedocuments. These documents also may

32、 be available in or throughlibraries or other informational services.)2j-splice -by the specific application.3.2.13.1 One-piece. The fabrication materials for one-pieceferrules shall be in accordance with MIL-F-21608 and applicabledrawings, or left to the discretion of the manufactuer, subject toaPP

33、roval of the Procuring activity and acceptable performance inaccordance with the requirements specified herein. The types andclasses on one-piece ferrules shall be determined by the specificapplication.3.2.13.2 Two-piece. The materials and design of the outerand inner ferrule shall be in accordance

34、with MIL-F-21608 andassociated standards or left to the discretion of the manufacturer,subject to approval of the procuring activity and acceptableperformance in accordance with the requirement specified lierein.Provided by IHSNot for ResaleNo reproduction or networking permitted without license fro

35、m IHS-,-,-MIL-E-457a2C3.2.14 Straps. Cable straps shall be in accordance with MIL-s-23190, MS 3367 or as specified on applicable drawings.3.3 Procedures. Procedures (see 6.4.11) for terminating andsplicing cable and harness assemblies and securing wire bundlesshall be as specified herein.3.3.1 Solde

36、ring. Soldering shall be in accordance with MIL-STD2000.3.3.2 Potting. If required by the procuring .activity,connectors shall be potted as specified on the applicable assemblydrawing (see 6.2).3.3.3 Shield termination. When ferrule shieldingterminations are being made, extreme care shall be exercis

37、ed inselecting the proper size ferrule rings and crimping tools toassure a reliable joint. Because of the danger of damaging theconductor insulation, solder shall not be used inmaking shieldingterminations with ferrules. All shields terminating with ferrulesShall have the ferrule assembly covered wi

38、th a snug, flexibleinsulating sleeve except where preinsulated ferrules are used. Thesleeve shall fit snugly over the ferrule assembly so that it doesnot slip during handling. The sleeve shall extend approximately0.250 inch beyond each ferrule end. A spot tie may be used betweeneach ferrule end and

39、the end of the insulating sleeve. Lacingcord, when required, shall be used for the spot tie. Clear heat-shrinkable sleeving may be used in lieu of the above, upon approvalof procuring activity. When a cable or harness assembly containsindividually shielded conductors, the shields may be terminatedwi

40、th the use of ferrules. If the assembly contains less than fiveindividuals shielded conductors, each shield may be terminated witheither a one- or two-piece ferrule assembly. The ferruleassemblies shall be staggered in the cable or harness as shown infigure 1 except where radio frequency interferenc

41、e attenuationrequirements demand that all ground leads to be the shortestpossible length. If the harness, cable, or wire bundles containsfive or more individually shielded conductors, each conductor shallbe prepared as described in 3.3.3.3.6 or 3.3.3.3.7.3.3.3.1 Jumpers. Jumpers and ground wires sha

42、ll befabricated from insuiatedr flexible, stranded wire (insulation oftype used in the assembly), or as specified on the detail drawing.In genqral, jumpers shall not cause strain on the terminationpoints.10Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-

43、,-,-MILE-45782C3.3.3.2 Ungrounded with ferrules. The procedure forterminating ungrounded shields with ferrules shall be the same asthat for gounded shields with ferrules, except that the groundinglead shall be omitted.3.3.3.3 Grounded with ferrules. Grounding of shielding withferrules shall be accom

44、plished by one of the following methods.3.3.3.3.1 Method A one-piece ferrules. The installation ofstandard one-piece ferrules (see 3.8 and 6.4.9) to terminate orground a braided shield shall be as follows:a Strip the insulation jacket, the braided shield, “and theconducorinsulation to the approximat

45、e length as shown in figure2.b. Flare the braid slightly by rotating the insulatedconductor as shown in figure 3.c. Select the proper ferrule by measuring the diameter of.-theconductor insulation and selecting theferrule in accordance“ithrespective dimensions shown, on applicable drawings.d. Select

46、the crimping dies recommended for the applicationin accordance with applicable drawings. Determine that thecrimping tool has been checked for proper adjustment. Gagesconforming to drawing requirements shall be used.Place ferrule in position, ferrule inner support ringunderehe cable shielding and the

47、 outer ring (as shown in figure 3)over the cable shielding as shown in figure 4.f. Place the ground wire between the braid and outer ring ofthe ferrule as shown in figure 5.9- Insert preassembled ferrule flush against the stop plateof the crimping tool (inspection holes of ferrule in visible andvert

48、ical position) as shown in figure 6 and close the crimping tooluntil dies are completely closed (dies closed to minimum opening orthe crimping tool ratchet releases) .h. Remove the crimped ferrule from the crimoina tool andexamine for proper crimp.-“When required by thedestrctive test samples shall.

49、 .contract or order (see 6.2),be prepared under production11Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-E-45782Cconditions in accordance with the sampling procedure specified (see4.5.3.2.2.2.1).3.3.3.3.1.1 Nonstandard ferrule (see 3.8 and 6.4.10).Installation procedures of procurin