ASD-STAN PREN 4199-001-2012 Aerospace series Bonding straps for aircraft Part 001 Technical specification (Edition P 2).pdf

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1、ASD-STAN STANDARD NORME ASD-STAN ASD-STAN NORM prEN 4199-001 Edition P 2 January 2012 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: Supersedes edi

2、tion P 1 of November 2002 and will supersede EN 4199-001:2006 Descriptors: ENGLISH VERSION Aerospace series Bonding straps for aircraft Part 001: Technical specification Srie arospatiale Tresses de mtallisation pour avion Partie 001 : Spcification technique Luft- und Raumfahrt Masseverbinder fr Luft

3、fahrzeuge Teil 001: Technische Lieferbedingungen This “Aerospace Series“ Prestandard has been drawn up under the responsibility of ASD-STAN (The AeroSpace and Defence Industries Association of Europe - Standardization). It is published for the needs of the European Aerospace Industry. It has been te

4、chnically approved by the experts of the concerned Domain following member comments. Subsequent to the publication of this Prestandard, the technical content shall not be changed to an extent that interchangeability is affected, physically or functionally, without re-identification of the standard.

5、After examination and review by users and formal agreement of ASD-STAN, it will be submitted as a draft European Standard (prEN) to CEN (European Committee for Standardization) for formal vote and transformation to full European Standard (EN). The CEN national members have then to implement the EN a

6、t national level by giving the EN the status of a national standard and by withdrawing any national standards conflicting with the EN. Edition approved for publication 1 January 2012 Comments should be sent within six months after the date of publication to ASD-STAN Electrical Domain Copyright 2011

7、by ASD-STAN prEN 4199-001:2012 (E) 2 Contents Page Foreword2 1 Scope 3 2 Normative references 3 3 Terms and definitions .3 4 Required characteristics.3 5 Design .4 6 Tests4 7 Quality assurance7 8 Designation . 10 9 Marking 10 10 Packaging 10 Foreword This standard was reviewed by the Domain Technica

8、l Coordinator of ASD-STANs Electrical Domain. After inquiries and votes carried out in accordance with the rules of ASD-STAN defined in ASD-STANs General Process Manual, this standard has received approval for Publication. prEN 4199-001:2012 (E) 3 1 Scope This standard specifies the general characte

9、ristics of bonding straps with flat or round braided copper conductor, and terminal lugs, crimped on both ends, for use on aircraft. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies.

10、 For undated references, the latest edition of the referenced document (including any amendments) applies. EN 2591*, Aerospace series Elements of electrical and optical connection Test methods EN 3373-001, Aerospace series Terminal lugs and in-line splices for crimping on electric conductors Part 00

11、1: Technical specification EN 3475*, Aerospace series Cables, electrical, aircraft use Test methods EN 9133, Aerospace series Quality management systems Qualification procedure for aerospace standard parts IEC 60050-581, International Electrotechnical Vocabulary Part 581: Electromechanical component

12、s for electronic equipment1)3 Terms and definitions For the purposes of this standard, the terms and definitions given in IEC 60050-581 and the following apply. a flat or round braided copper conductor, tin or nickel plated; crimped on terminal lugs at both ends. 4 Required characteristics 4.1 Gener

13、al See product standard. 4.2 Temperature range See Table 1. * All its parts quoted in this standard. 1)Published by: IEC International International Electrotechnical Commission http:/www.iec.ch/.prEN 4199-001:2012 (E) 4 Table 1 Class Temperature range Material/finish T 65 C to 150 C Tin plated coppe

14、r braided conductor and tin plated copper terminal lugs N 65 C to 260 C Nickel plated copper braided conductor and nickel plated copper terminal lugs 4.3 Material Materials shall be suitable for the intended use and as specified in the product standard. 4.4 Finish See product standard. 4.5 Dimension

15、s and mass See product standard. 5 Design Bonding straps for aircraft shall be designed and assembled in a careful and workmanlike manner such as to withstand normal handling during installation and maintenance in service. In order to achieve good reliable crimped connections the correct crimping to

16、ol shall be used. When using bonding straps on equipment or installations generating or processing frequencies greater than 100 kHz, care shall be taken not to exceed a length to width ratio of five to one for reasons of electromagnetic compatibility. 6 Tests 6.1 Tests on the braids The tests of EN

17、3475 listed in Table 2 shall be applicable for testing of round and flat braid conductors used in the construction of bonding straps. Table 2 EN 3475- Designation of the test Details 201 Visual examination No visible deformations. 202 Mass Mass, shall be carried out on each batch of material. 203 Di

18、mensions Including correct braid angle when applicable see product standard. 301 Ohmic resistance per unit length Table, see product standard. 512 Flexure endurance As specified in the product standard. prEN 4199-001:2012 (E) 5 6.2 Tests on the bonding strap assemblies The tests of EN 2591, applicab

19、le in the context of this standard as well as the details necessary for implementing them and for inspecting bonding straps are given in Table 3 of this standard. Table 3 EN 2591- Designation of the test Details 101 Visual examination Initial examined details to be examined: identification of materi

20、als in accordance with product standard; identification; appearance; marking; surface finish; final examination. 102 Examination of dimensions and mass As defined in product standard. 218 Ageing of terminal lugs and in-line splices by temperature and current cycling Test current and initial voltage

21、drop as specified in product standard. Maximum deviation at end of test shall not exceed that specified in EN 2591-218. 301 Endurance at temperature Method B 20 h in dry heat at temperature of (150 5) C for tin plated or (260 5) C for nickel plated bonding straps. No deviation from tensile strength

22、listed in this standard and from maximum permissible voltage drop specified in the appropriate product standard. 305 Rapid change of temperature Temperature cycles: Five cycles after variations 65 C to 150 C for tin plated, 65 C to 260 C for nickel plated bonding straps. No deviation from tensile st

23、rength listed in this standard and from maximum permissible voltage drop specified in the appropriate product standard. 307 Salt mist 48 h or as specified in the product standard. No deviation from maximum permissible voltage drop specified in the appropriate product standard 403 Sinusoidal and rand

24、om vibration Not applicable 417 Tensile strength (crimped connection) EN 3373-001, terminal lugs on both ends. The specimen shall not break at a value less than that specified in the product standard. prEN 4199-001:2012 (E) 6 6.3 Ohmic resistance The ohmic resistance and test current values for comp

25、lete bonding strap assemblies shall be defined in the product standard. The resistance shall be calculated from the voltage drop readings measured in accordance with Figure 1 or Figure 2 at (20 3) C. Figure 1 Bonding straps with flat braid conductor Figure 2 Bonding straps with round braid conductor

26、 6.4 Mechanical fatigue test Specimens shall be bonding straps assembled with a terminal at each end, the dimension between the stud holes being 250 mm centre to centre. The specimen shall be mounted on the test apparatus as shown in Figure 3, the axis of the terminal lugs passing through the pivot

27、point of the apparatus. One test cycle shall consist of one flex to 50 upwards, return to neutral position followed by flex to 50 downwards and then return to the neutral, starting, position. The specimen shall be flexed for the number of cycles detailed in the product standard. A visual examination

28、 and test 6.3 shall be performed after the required number of cycles has been completed. Failure of the specimen is deemed to be a complete fracture or when the resistance reading exceeds the specified requirement by more than 20 %. The results shall be reported. prEN 4199-001:2012 (E) 7 6.5 Mechani

29、cal fatigue test apparatus See Figure 3. Top view Key 1 Screw and washer 2 Articulation 3 Mobile part of tool 4 Fixed part of tool 5 Spacer 6 Up + 50 7 Down 50 Figure 3 Mounting device 7 Quality assurance 7.1 General See EN 9133. prEN 4199-001:2012 (E) 8 7.2 Qualification Qualification testing shall

30、 be carried out at the commencement of manufacture or at recommencement if there has been a stoppage in manufacture for more than three years or if there has been any change in components or tooling. The tests shall be carried out in the sequences listed in Tables 3 and 4 on representative types and

31、 sizes of conductors and assemblies as agreed with the Mandated Body. Qualification of other types and sizes closely related to those already qualified may be obtained directly by similarity or by carrying out a reduced range of tests by agreement with the Mandated Body. 7.2.1 Qualification of braid

32、s and conductors See Table 3. Table 3 EN 3475- Designation of the test Details 201 Visual examination No visible deformations, correct angle of braid where applicable 202 Mass See product standard. 203 Dimensions See product standard. 301 Ohmic resistance per unit length See product standard. 512 Fl

33、exure endurance See product standard. 7.2.2 Qualification of bonding strap assemblies See Table 4. Only bonding straps assembled from certified components and using certified calibrated tooling shall be qualified. Table 4 Designation of the test EN 2591- Remarks Group 0 12 specimens Visual examinati

34、on 101Examination of dimensions and mass 102 See product standard. Voltage drop (see 6.3) See product standard. Group 1 3 specimens Tensile strength (crimped connection) 417 See product standard. Group 2 3 specimens Ageing of terminal lugs and in-line splices by temperature and current cycling 218 S

35、ee product standard. Tensile strength (crimped connection) 417 continued prEN 4199-001:2012 (E) 9 Table 4 (concluded) Designation of the test EN 2591- Remarks Group 3 3 specimens Mechanical Fatigue (see 6.4) 10 % of the required number of flex cycles specified in the product standard Salt mist 307 4

36、8 h or as product standardRapid change of temperature 305 Endurance at temperature 301 Visual examination 101 Voltage drop (see 6.3)a See product standard. Tensile strength (crimped connection) 417 See product standard. Group 4 3 specimens Salt mist 307 48 h or as product standardMechanical fatigue

37、test (see 6.4) See product standard. Visual examination 101 Voltage drop (see 6.3)a See product standard. Tensile strength (crimped connection) 417 See product standard. aThe maximum value of resistance measured in test groups 3 and 4 shall be not greater than the maximum value specified for initial

38、 resistance plus 20 % when measured using the current specified in the product standard. 7.3 Maintenance of qualification The sequence of tests shall be required at a minimum of three years for equipment in production or when production is restarted in the event of a stoppage in manufacture for more

39、 than three years. For braid, the tests in Table 4 shall be carried out and for bonding straps assemblies, the tests in group 4 of Table 4. 7.4 Acceptance Tests The tests listed in Tables 5 and 6 shall be carried out on each batch of material, whichever is the smaller. 7.4.1 Tests for round and flat

40、 braid conductors See Table 5. Table 5 EN 3475- Designation of the test Details 201 Visual examination All specimens 203 Dimensions All specimens 301 Ohmic resistance per unit length All specimens prEN 4199-001:2012 (E) 10 7.4.2 Tests for bonding strap assemblies See Table 6. Table 6 EN 2591- Design

41、ation of the test Details 101 Visual examination All specimens 102 Examination of dimensions and mass All specimens (Dimensions only) Ohmic resistance (see 6.3) One specimen per production batch 8 Designation See product standard. 9 Marking See product standard. 10 Packaging Bonding straps shall be so packed as to avoid any damage.