BS EN 16602-70-26-2014 Space product assurance Crimping of high-reliability electrical connections《航天产品保证 高可靠性电连接中的压接》.pdf

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1、BSI Standards PublicationBS EN 16602-70-26:2014Space product assurance Crimping of high-reliabilityelectrical connectionsBS EN 16602-70-26:2014 BRITISH STANDARDNational forewordThis British Standard is the UK implementation ofEN 16602-70-26:2014.The UK participation in its preparation was entrusted

2、to Technical Committee ACE/68, Space systems and operations.A list of organizations represented on this committee can be obtained on request to its secretary.This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Th

3、e British Standards Institution 2014.Published by BSI Standards Limited 2014ISBN 978 0 580 84595 6 ICS 49.060; 49.140 Compliance with a British Standard cannot confer immunity from legal obligations.This British Standard was published under the authority of the Standards Policy and Strategy Committe

4、e on 30 November 2014.Amendments/corrigenda issued since publicationDate T e x t a f f e c t e dEUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 16602-70-26 October 2014 ICS 49.060; 49.140 English version Space product assurance - Crimping of high-reliability electrical connections Assurance pro

5、duit des projets spatiaux - Sertissage des connexions lectriques fiabilit leve Raumfahrtproduktsicherung - Quetschen von hochzuverlssigen elektrischen Verbindungen This European Standard was approved by CEN on 11 April 2014. CEN and CENELEC members are bound to comply with the CEN/CENELEC Internal R

6、egulations 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 standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN a

7、nd CENELEC member. This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN and CENELEC member into its own language and notified to the CEN-CENELEC Management Centre has the same status

8、as the official versions. CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ir

9、eland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom. CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels 2014 CEN/CENELEC All rights of exploitation in any form and

10、by any means reserved worldwide for CEN national Members and for CENELEC Members. Ref. No. EN 16602-70-26:2014 EBS EN 16602-70-26:2014Table of contents Foreword 5 1 Scope . 6 2 Normative references . 8 3 Terms, definitions and abbreviated terms 9 3.1 Terms defined in other standards . 9 3.2 Terms sp

11、ecific to the present standard . 9 3.3 Abbreviated terms. 10 4 Principles 11 5 Requirements 12 5.1 Preparatory conditions 12 5.1.1 Facilities 12 5.1.2 Tools and equipment . 13 5.2 Crimping operations for specific interconnections . 14 5.2.1 General . 14 5.2.2 Material selection 15 5.2.3 Process revi

12、ew and documentation . 15 5.2.4 Connector barrel and single wire crimping 16 5.2.5 Connector barrel and multiple wire crimping 16 5.2.6 Ferrule shield crimping 17 5.2.7 Lug and splice wire crimping . 18 5.3 Requirements for new crimp configurations 19 5.3.1 General . 19 5.3.2 Test procedure 19 5.3.3

13、 Sealing and marking . 20 5.4 Test methods 21 5.4.1 General . 21 5.4.2 Voltage drop 21 5.4.3 Tensile strength 23 5.4.4 Metallography . 26 EN 16602-70-26:2014 (E)BS EN 16602-70-26:20145.5 Quality assurance . 26 5.5.1 General . 26 5.5.2 Personnel training and certification . 27 5.5.3 Workmanship 29 5.

14、5.4 Visual inspection . 30 5.5.5 Shift performance inspection and test . 31 5.5.6 Calibration of crimping tools 31 5.5.7 Records 32 5.5.8 Nonconformance . 33 5.6 Document requirements 33 Annex A (informative) Crimp configurations and tools . 34 Bibliography . 40 Figures Figure 1-1: Specific intercon

15、nections in this Standard 7 Figure 5-1: Example of a typical connector barrel and single wire crimping 16 Figure 5-2: Example of a typical connector barrel and multi-wire crimping 17 Figure 5-3: Example of a typical ferrule shield crimping 18 Figure 5-4: Examples of typical lug and splice wire crimp

16、ing 19 Figure 5-5: Typical plots showing variation in crimp termination characteristics with increasing indentation depth . 21 Figure 5-6: Measurement of voltage drop across a crimped termination . 22 Figure 5-7: Quality control during crimping operation . 28 Figure 5-8: Visible workmanship standard

17、s 29 Figure 5-9: Workmanship examples and crimp micro-sections . 29 Figure A-1 : Confined irregular-octagon crimp (compactive) . 35 Figure A-2 : Dimpled confined octagon crimp (compactive) 35 Figure A-3 : Regular-hexagon crimp (compactive) 35 Figure A-4 : Semicircular one- or two-indent crimp (dispe

18、rsive) 35 Figure A-5 : Four-indent crimp (dispersive) . 35 Figure A-6 : Typical test fixture for testing lug and splice crimps . 39 Tables Table 5-1: Equipment for verification process . 14 Table 5-2: Voltage drop test requirements 23 Table 5-3: Required ultimate axial strength for compactive and di

19、spersive crimped joints 25 EN 16602-70-26:2014 (E)BS EN 16602-70-26:2014Table A-1 : Guideline for selector setting - Four-indent crimp (dispersive) Single wire (Crimping tool 22520/2-01) . 37 Table A-2 : Guideline for selector setting - Four-indent crimp (dispersive) -Two wires (Crimping tool 22520/

20、2-01) . 38 Table A-3 : Guideline for die selection (ferrule coaxial shield crimping) 38 EN 16602-70-26:2014 (E)BS EN 16602-70-26:2014Foreword This document (EN 16602-70-26:2014) has been prepared by Technical Committee CEN/CLC/TC 5 “Space”, the secretariat of which is held by DIN. This standard (EN

21、16602-70-26:2014) originates from ECSS-Q-ST-70-26C. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by April 2015, and conflicting national standards shall be withdrawn at the latest by April 2015. A

22、ttention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN and/or CENELEC shall not be held responsible for identifying any or all such patent rights. This document has been prepared under a mandate given to CEN by the European Commission

23、 and the European Free Trade Association. This document has been developed to cover specifically space systems and has therefore precedence over any EN covering the same scope but with a wider domain of applicability (e.g. : aerospace). According to the CEN-CENELEC Internal Regulations, the national

24、 standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuan

25、ia, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. EN 16602-70-26:2014 (E)BS EN 16602-70-26:20141 Scope This Standard specifies: Requirements for the following crimping wire terminations intended for h

26、igh reliability electrical connections for use on customer spacecraft and associated equipment operating under high vacuum, thermal cycling and launch vibration: removable contacts, single wires removable contacts, multiple wires coaxial connectors, ferrules lugs and splices. NOTE These are the most

27、 common used crimping wire termination and are represented in Figure 1-1. The general conditions to be met for the approval of terminations other than the above mentioned ones. NOTE Additional forms of crimps, not covered in this standard, are listed (not exhaustively) in the informative Annex A. Pr

28、oduct assurance provisions for both the specific and the generic terminations mentioned above. Training and certification requirements for operators and inspectors (clause 5.5.2), additional to those specified in ECSS-Q-ST-20. This standard may be tailored for the specific characteristics and constr

29、aints of a space project, in conformance with ECSS-S-ST-00. EN 16602-70-26:2014 (E)BS EN 16602-70-26:2014Figure 1-1: Specific interconnections in this Standard EN 16602-70-26:2014 (E)BS EN 16602-70-26:20142 Normative references The following normative documents contain provisions which, through refe

30、rence in this text, constitute provisions of this ECSS Standard. For dated references, subsequent amendments to, or revisions of any of these publications do not apply. However, parties to agreements based on this ECSS Standard are encouraged to investigate the possibility of applying the most recen

31、t editions of the normative documents indicated below. For undated references the latest edition of the publication referred to applies. EN reference Reference in text Title EN 16601-00-01 ECSS-S-ST-00-01 ECSS system - Glossary of terms EN 16602-10-09 ECSS-Q-ST-10-09 Space product assurance - Noncon

32、formance control system EN 16602-20 ECSS-Q-ST-20 Space product assurance - Quality assurance EN 16602-60 ECSS-Q-ST-60 Space product assurance - Electrical, electronic and electromechanical (EEE) components EN 16602-70 ECSS-Q-ST-70 Space product assurance - Materials, mechanical parts and processes E

33、N 16602-70-08 ECSS-Q-ST-70-08 Space product assurance - Manual soldering of high-reliability electrical connections EN 16602-70-38 ECSS-Q-ST-70-38 Space product assurance - High-reliability soldering for surface-mount and mixed technology EN 16602-70-71 ECSS-Q-ST-70-71 Space product assurance - Data

34、 for selection of space materials and processes MIL-DTL-22520G Crimping tools, terminal hard, wire termination, general specification for NASA-STD-8739.4/CHG3 09/05/2006 Crimping, Interconnection cables, harnesses and wiring SAE-AS-7928A 02/01/2008 Terminals, lugs, splices, conductor, crimp style, c

35、opper, general specification for SAE-AS-81824 08/01/1998 Splices, electric, permanent, crimp style, copper, insulated, environment resistant EN 16602-70-26:2014 (E)BS EN 16602-70-26:20143 Terms, definitions and abbreviated terms 3.1 Terms defined in other standards For the purpose of this Standard,

36、the terms and definitions from ECSS-S-ST-00-01 and ECSS-Q-ST-70-38 apply, in particular for the following terms: electrical connections process identification document (PID) NOTE The DRD for the PID is given in ECSS-Q-ST-70-38. 3.2 Terms specific to the present standard 3.2.1 adjustable indenter too

37、l crimping tool which has an adjustable part (setting variable) that indents or compresses the conductor barrel or ferrule 3.2.2 crimping tool mechanical tool used for permanently attaching a wire termination device to a conductor by pressure deformation or by reshaping the barrel around the conduct

38、or to establish good electrical and mechanical contact 3.2.3 ferrule short metal tube used to make crimp connections to the outer conductor of shielded or coaxial cables 3.2.4 lug metallic tube with drilled flange projection for fixing to threaded terminal 3.2.5 splice device for joining two or more

39、 conductors to each other 3.2.6 terminal metallic device that is used for making electrical connections EN 16602-70-26:2014 (E)BS EN 16602-70-26:20143.3 Abbreviated terms For the purpose of this Standard, the abbreviated terms from ECSS-S-ST-00-01 and the following apply: Abbreviation Meaning AWG Am

40、erican wire gauge QA quality assurance PID process identification document RFA request for approval RH relative humidity EN 16602-70-26:2014 (E)BS EN 16602-70-26:20144 Principles This Standard is structured such that the necessary level of quality is achieved and consistently maintained, and high re

41、liability of the end product assured. The following principles are covered: Preparatory conditions determine the availability of facilities, tools and equipment, along with obligatory hazard and health precautions. Specific interconnections, as identified in the Scope above, are then covered in deta

42、il including Material selection, and Process identification and documentation. New crimp configurations beyond those identified above. Test methods and acceptance criteria for both specific and generic types of interconnections are specified. Quality assurance measures for both the operator and the

43、inspector are prescribed Training and certification of personnel, Workmanship standards and acceptance criteria, Inspection criteria and sequence, Calibration of tools and equipment, Records from material income through delivery of the end product, including the handling of deviations by RFA or NCR.

44、 It is important to perform the work taking into account health and safety regulations, and in particular the national standards on this subject. EN 16602-70-26:2014 (E)BS EN 16602-70-26:20145 Requirements 5.1 Preparatory conditions 5.1.1 Facilities 5.1.1.1 Overview The requirements in this clause c

45、an generally be met by using cleanrooms. It is not, however, mandatory to use a cleanroom. 5.1.1.2 Facility cleanliness a. The supplier shall provide cleaning services for production facilities of high reliability crimping. b. The areas, in which crimping is carried out, shall be maintained in an or

46、derly fashion. c. Loose material that can cause contamination of the crimped connection shall be removed. NOTE For example: Dirt, dust, oils and clipped wires. d. Furniture shall be kept to a minimum in the work areas and be arranged to allow easy and thorough cleaning of the floor. e. Working surfa

47、ces shall be covered with an easily cleaned hard top or have a replaceable surface of clean, non-corrosive silicone-free paper. 5.1.1.3 Environmental conditions a. The crimping area shall have a controlled environment, which limits entry of contamination. b. The area shall be continuously controlled

48、 as follows: 1. room temperature: (22 3) C; 2. relative humidity: (55 10) %. c. The workstations shall not be exposed to draughts. d. Fresh air shall be supplied to the room through a filtering system with positive pressure difference with regard to adjacent rooms. e. The exhaust air shall be suitab

49、ly restricted. EN 16602-70-26:2014 (E)BS EN 16602-70-26:20145.1.1.4 Lighting requirements a. The supplier shall ensure adequate illumination conditions of the crimp workstations. b. The light intensity shall be 1 080 lux on the work surface. c. 90 % of the work area shall be shadowless and without severe reflections. 5.1.2 Tools and equipment 5.1.2.1 Crimping tools a. The supplier shall provide the tooling necessary for continued high quality crimping. b. Tools used shall employ an integral mechanism, which controls the crimping opera