SIST EN 16602-70-26:2015
(Main)Space product assurance - Crimping of high-reliability electrical connections
Space product assurance - Crimping of high-reliability electrical connections
This Standard specifies:
• Requirements for the following crimping wire terminations intended for high 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 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.
• Product 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 constraints of a space project, in conformance with ECSS-S-ST-00.
Raumfahrtproduktsicherung - Quetschen von hochzuverlässigen elektrischen Verbindungen
Assurance produit des projets spatiaux - Sertissage des connexions électriques à fiabilité élevée
La présente norme spécifie :
• Les exigences applicables aux terminaisons de fils serties destinées aux connexions électriques de haute fiabilité devant être utilisées sur les engins spatiaux et équipements associés, destinés au client, dans des conditions de vide poussé, de cyclage thermique et de vibrations dues au lanceur :
contacts amovibles, fils simples,
contacts amovibles, fils multiples,
connecteurs coaxiaux, ferrules,
languettes de contact et épissures.
NOTE Il s'agit-là des terminaisons de fils serties les plus couramment utilisées. Elles sont représentées sur la Figure 1-1.
• Les conditions générales à remplir en vue de l'approbation des terminaisons autres que celles qui sont mentionnées ci-dessus.
NOTE L'Annexe informative A répertorie d'autres formes de sertissage, non couvertes par la présente norme (liste non exhaustive).
• Les dispositions en matière d'assurance produit relatives aux terminaisons spécifiques et génériques mentionnées ci-dessus.
• les exigences relatives à la formation et à la certification des opérateurs et des inspecteurs (paragraphe 5.5.2), qui complètent celles qui sont spécifiées dans l'ECSS Q ST-20.
La présente norme peut être adaptée aux caractéristiques et contraintes spécifiques d'un projet spatial, conformément à l'ECSS-S-ST-00.
...
Figure 1 1 : Interconnexions spécifiques mentionnées dans la présente norme
Zagotavljanje varnih proizvodov v vesoljski tehniki - Stiskalno spajanje kontaktov visoko zanesljivih električnih konektorjev
Ta standard določa: • Zahteve za naslednje žične priključke za stiskalno spajanje, namenjene za visoko zanesljive električne konektorje za uporabo na vesoljskih plovilih in povezani opremi odjemalca, ki delujejo pri visokem vakuumu, toplotnih cikličnih obremenitvah in vibracijah ob izstrelitvi: – odstranljive kontakte, posamezne žice, – odstranljive kontakte, več žic, – koaksialne konektorje, tulke, – ročaje in spojnice. OPOMBA: To so najpogosteje uporabljani žični priključki za stiskalno spajanje in so predstavljeni na sliki 1.1. • Splošne pogoje, ki jih je treba izpolnjevati za odobritev priključkov, razen že zgoraj navedenih. OPOMBA: Dodatne oblike kodrov, ki niso obravnavane v tem standardu, so navedene (ne izčrpno) v informativnem dodatku A. • Določbe za zagotavljanje varnih proizvodov za posamezne in splošne priključke, navedene zgoraj. • Zahteve za usposabljanje in potrjevanje za upravljavce in inšpektorje (točka 5.5.2) poleg zahtev iz standarda ECSS Q ST-20. Ta standard se lahko prilagodi posameznim lastnostim in omejitvam vesoljskega projekta v skladu s standardom ECSS-S-ST-00.
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN 16602-70-26:2015
01-januar-2015
=DJRWDYOMDQMHYDUQLKSURL]YRGRYYYHVROMVNLWHKQLNL6WLVNDOQRVSDMDQMHNRQWDNWRY
YLVRNR]DQHVOMLYLKHOHNWULþQLKNRQHNWRUMHY
Space product assurance - Crimping of high-reliability electrical connections
Raumfahrtproduktsicherung - Quetschen von hochzuverlässigen elektrischen
Verbindungen
Assurance produit des projets spatiaux - Sertissage des connexions électriques à fiabilité
élevée
Ta slovenski standard je istoveten z: EN 16602-70-26:2014
ICS:
49.060 /HWDOVNDLQYHVROMVND Aerospace electric
HOHNWULþQDRSUHPDLQVLVWHPL equipment and systems
49.140 Vesoljski sistemi in operacije Space systems and
operations
SIST EN 16602-70-26:2015 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST EN 16602-70-26:2015
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SIST EN 16602-70-26:2015
EUROPEAN STANDARD
EN 16602-70-26
NORME EUROPÉENNE
EUROPÄISCHE NORM
October 2014
ICS 49.060; 49.140
English version
Space product assurance - Crimping of high-reliability electrical
connections
Assurance produit des projets spatiaux - Sertissage des Raumfahrtproduktsicherung - Quetschen von
connexions électriques à fiabilité élevée hochzuverlässigen 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 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 standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN and 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 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, Ireland, 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 by any means reserved Ref. No. EN 16602-70-26:2014 E
worldwide for CEN national Members and for CENELEC
Members.
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Table 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 specific 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 review 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 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
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5.5 Quality assurance . 26
5.5.1 General . 26
5.5.2 Personnel training and certification . 27
5.5.3 Workmanship . 29
5.5.4 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 interconnections 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 crimping . 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 standards . 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 (dispersive) . 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 dispersive crimped
joints . 25
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Table 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 22520/2-01) . 38
Table A-3 : Guideline for die selection (ferrule coaxial shield crimping) . 38
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Foreword
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 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.
Attention 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 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
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, Lithuania, Luxembourg, Malta, Netherlands,
Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden,
Switzerland, Turkey and the United Kingdom.
5
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1
Scope
This Standard specifies:
• Requirements for the following crimping wire terminations intended for
high 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 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.
• Product 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 constraints of a
space project, in conformance with ECSS-S-ST-00.
6
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Figure 1-1: Specific interconnections in this Standard
7
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2
Normative references
The following normative documents contain provisions which, through
reference 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 recent 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 - Nonconformance 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
EN 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 for selection of
space materials and processes
MIL-DTL-22520G Crimping tools, terminal hard, wire termination,
general specification for
NASA-STD-8739.4/CHG3 Crimping, Interconnection cables, harnesses and
09/05/2006 wiring
SAE-AS-7928A Terminals, lugs, splices, conductor, crimp style,
02/01/2008 copper, general specification for
SAE-AS-81824 Splices, electric, permanent, crimp style, copper,
08/01/1998 insulated, environment resistant
8
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3
Terms, definitions and abbreviated terms
3.1 Terms defined in other standards
For the purpose of this Standard, 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 tool
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
conductor 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 conductors to each other
3.2.6 terminal
metallic device that is used for making electrical connections
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3.3 Abbreviated terms
For the purpose of this Standard, the abbreviated terms from ECSS-S-ST-00-01
and the following apply:
Abbreviation Meaning
American wire gauge
AWG
quality assurance
QA
process identification document
PID
request for approval
RFA
relative humidity
RH
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4
Principles
This Standard is structured such that the necessary level of quality is achieved
and consistently maintained, and high reliability 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 detail 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 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.
It is important to perform the work taking into account health and safety
regulations, and in particular the national standards on this subject.
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5
Requirements
5.1 Preparatory conditions
5.1.1 Facilities
5.1.1.1 Overview
The requirements in this clause can 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
orderly 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 surfaces 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 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 suitably restricted.
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5.1.1.4 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 operation in conformance to MIL-DTL-22520G.
NOTE The mechanism ensures that, once the operation is
started, the tool cannot be opened until the
crimping cycle is complete.
c. Tools shall be marked to show the size and type of termination for which
it is calibrated.
d. Tool calibration shall be verified once each shift in conformance with the
clause 5.5.5 requirements.
e. Proper operation of the integral ratcheting mechanism or the positive
stops on pneumatic tools shall be verified as defined in clause 5.5.6.
f. Before starting a crimping process on a new terminal size and wire type,
tools used for crimping of the previous wire type shall be returned to the
tool facility.
g. If the tool settings seals are broken, the tool shall be returned
immediately for recalibration.
h. Tools used in the crimping operation shall be clean; excess lubricants
shall be removed before crimping starts.
5.1.2.2 Insulation strippers
a. The supplier shall provide the tooling necessary to avoid damage to the
conductor.
b. The selection of thermal or precision cutting devices, manual or
automatic power-driven, shall provide protection of the conductor
strands.
c. Wire stretching by use of mechanical strippers shall be avoided.
d. The conductor shall not be twisted, ringed, nicked, cut or scored by
stripping operation.
e. Both thermal and mechanical stripping tools shall be calibrated
periodically on sample evaluation during a production run.
5.1.2.3 Cutters and pliers
a. The supplier shall provide the tooling necessary for precision wire
trimming and cutting.
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b. The cutter used for trimming conductor wire shall shear sharply and
consistently produce a clean, flat, smooth-cut surface along the entire
cutting edge.
c. Twisting action during cutting operation shall be avoided.
d. Smooth, long-nose pliers or tweezers shall be used for attaching or
removing conductor wire.
e. The cutting edges of pliers shall be regularly checked for damage and
maintained in a sharp condition.
5.1.2.4 Test and monitoring equipment
a. The supplier shall provide the equipment specified in Table 5-1 necessary
for verification activities specified in clauses 5.4.2 and 5.4.3.
Table 5-1: Equipment for verification process
Performance tests activity Equipment characteristic
Voltage-drop (in conformance with 0 A - 150 A current source and 0 mV -
clause 5.4.2 requirements) 10 mV voltmeter
Tensile strength (in conformance Tensile testing machine 0 N - 4000 N, accurate to
with clause 5.4.3 requirements) 1 % of full scale load, axial load applied at a rate
of (25 – 50) mm/min ±2 mm/min
Visual inspection Microscope magnification ×7 to ×400
Monitoring requirements of the
process
Temperature 15 °C to 30 °C, accurate to ±1 °C
Relative humidity (RH) 40 % to 70 %, accurate to ±1 %
5.2 Crimping operations for specific interconnections
5.2.1 General
a. The supplier shall visually examine wire, terminal and connector contacts
for cleanliness, absence of oil films and freedom from tarnish or corrosion
before assembly.
b. The supplier shall perform cleaning of the work pieces in conformance
with ECSS-Q-ST-70-08.
c. Further cleaning or other treatment shall not be carried out.
d. The supplier shall handle work pieces with clean lint free gloves or finger
cots.
e. Before a crimping activity, tools at the operator’s station shall be verified
to conform to those selected in accordance with the applicable PID.
f. All conductor strands shall be inserted cleanly into the barrel without
any buckling.
g. Strands shall not be left outside or cut back to reduce the conductor
diameter to fit an undersized barrel.
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h. The supplier shall use tools specified in MIL-DTL-22520.
NOTE Examples of crimping parameters are given in
Table A-2 and Table A-3
i. The supplier shall take provisions to avoid degradation of the silver
plated wire caused by tarnish during storage.
j. In cases when the same wire is joined later by soldering, the solder fluxes
prescribed in ECSS-Q-ST-70-08 shall be used to avoid degradation.
NOTE For shift performance inspection requirements see
clause 5.5.5.
5.2.2 Material selection
a. The supplier shall use silver plated copper multi stranded wire and
braided shield cable in crimp type connectors.
b. Exceptional cases when nickel- or tin-plated wires are used shall be
approved by the customer through a request for approval (RFA), in
conformance with ECSS-Q-ST-70, clause 5.1.4.
c. The supplier shall use high strength copper alloy wire for 24 AWG,
26 AWG and 28 AWG crimped joints.
NOTE Soft or annealed copper wire are not acceptable for
crimped joints of 24 AWG, 26 AWG and 28 AWG
size.
d. The supplier shall use space-qualified components having gold plated
terminals in conformance with ECSS-Q-ST-60.
e. Specific terminals such as ferrules, splices and lugs shall be purchased to
MIL or SAE-AS-7928 specifications.
f. When gold plating is not available the finish shall be in conformance with
ECSS-Q-ST-70-71.
g. Cadmium, chromate-coated cadmium and non-fused tin-plating shall not
be used.
5.2.3 Process review and documentation
a. The supplier shall perform a review of all the materials, tools and
techniques planned to be used to ensure conformance to requirements of
this standard and as a means of identifying potential problems.
NOTE Type of wire includes number of strands, plating
metal, type and thickness of insulation.
b. Dies, setting of controls for the length of strip in automatic stripping
machines and the selection of specific locators or positioners, shall be
selected to meet process requirements.
NOTE The requirement is valid for power driven and
manual crimping processes as well as for size and
tolerance for crimping tools
c. The results of the review shall be documented in a PID in conformance
with DRD of ECSS-Q-ST-70-38.
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5.2.4 Connector barrel and single wire crimping
a. The supplier shall give preference to the selection of single wire
interconnections.
b. The supplier shall not use strands of wire doubled backed to increase the
conductor diameter.
c. The supplier shall use additional stranded wires to increase the cross-
sectional area up to a selected barrel size;
NOTE The requirement is applied for cases where the
insulation is prepared as normal and transparent
“shrink-fit insulation” to cover the loose end of the
wire to prevent any risk of a short circuit.
d. For 28 AWG up to 16 AWG wire sizes, the maximum insulation clearance
shall be equal to the outside diameter (over the insulation) of the wire
being used.
e. The gaps for larger size wires shall not exceed 2 mm.
NOTE No minimum gap is specified except that the
conductor wire shall be visible to permit inspection.
f. Where the terminal or contact is supplied with insulation support, the
wire insulation shall enter the support to the extent that no bare wire is
exposed.
NOTE An example of a typical connector barrel and
single wire crimping is shown Figure 5-1.
Figure 5-1: Example of a typical connector barrel and single wire crimping
5.2.5 Connector barrel and multiple wire crimping
a. Requirements of this clause shall be applied when single wire crimping
cannot be used.
b. The maximum number of wires in one crimp barrel shall be two.
c. The sum of the two nominal conductor sections shall be compatible with
the crimp barrel used
NOTE 2 × 24 AWG is approximately equal to 1 × 20 AWG.
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d. Both conductors shall be of the same material and support the same
plating finish.
NOTE 1 For example: Both are silver and not a combination
of silver and nickel
NOTE 2 Before introduction into the barrel wires or
conductors can be twisted to obtain a “single”
conductor.
e. Axial strength measurements shall be performed on the two associated
wires and the axial strength shall be 75 % of the sum of the two wires
axial strength requirements.
f. For separate conductors introduced into the barrel the following shall
apply:
1. the actual strength measurement is performed on one of the wires
(the smaller, if two different sizes are used);
2. the axial strength requirement is as quoted in Table 5-3 for the
actual size of wire pulled, assuming a barrel size equal to that
wire’s gauge.
NOTE Examples of crimping parameters are given in Table
A-1 and an example of a typical connector barrel and
multi-wire crimping is shown in Figure 5-2.
Figure 5-2: Example of a typical connector barrel and multi-wire crimping
5.2.6 Ferrule shield crimping
a. The shielded wires on coaxial cables shall be braided.
b. Axial stre
...
SLOVENSKI STANDARD
kSIST FprEN 16602-70-26:2014
01-februar-2014
=DJRWDYOMDQMHYDUQLKSURL]YRGRYYYHVROMVNLWHKQLNL6WLVNDOQRVSDMDQMHNRQWDNWRY
YLVRNR]DQHVOMLYLKHOHNWULþQLKNRQHNWRUMHY
Space product assurance - Crimping of high-reliability electrical connections
Raumfahrtproduktsicherung - Quetschen von hochzuverlässigen elektrischen
Verbindungen
Assurance produit des projets spatiaux - Sertissage des connexions électriques à fiabilité
élevée
Ta slovenski standard je istoveten z: FprEN 16602-70-26
ICS:
49.060 /HWDOVNDLQYHVROMVND Aerospace electric
HOHNWULþQDRSUHPDLQVLVWHPL equipment and systems
49.140 Vesoljski sistemi in operacije Space systems and
operations
kSIST FprEN 16602-70-26:2014 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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kSIST FprEN 16602-70-26:2014
EUROPEAN STANDARD
FINAL DRAFT
FprEN 16602-70-26
NORME EUROPÉENNE
EUROPÄISCHE NORM
October 2013
ICS 49.060; 49.140
English version
Space product assurance - Crimping of high-reliability electrical
connections
Assurance produit des projets spatiaux - Sertissage des Raumfahrtproduktsicherung - Quetschen von
connexions électriques à fiabilité élevée hochzuverlässigen elektrischen Verbindungen
This draft European Standard is submitted to CEN members for unique acceptance procedure. It has been drawn up by the Technical
Committee CEN/CLC/TC 5.
If this draft becomes a European Standard, CEN and 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.
This draft European Standard was established by CEN and CENELEC 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 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, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia,
Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are aware and to
provide supporting documentation.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.
CEN-CENELEC Management Centre:
Avenue Marnix 17, B-1000 Brussels
© 2013 CEN/CENELEC All rights of exploitation in any form and by any means reserved Ref. No. FprEN 16602-70-26:2013 E
worldwide for CEN national Members and for CENELEC
Members.
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Table 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 specific 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 review 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 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
2
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5.5 Quality assurance . 26
5.5.1 General . 26
5.5.2 Personnel training and certification . 27
5.5.3 Workmanship . 29
5.5.4 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 interconnections 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 crimping . 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 standards . 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 (dispersive) . 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 dispersive crimped
joints . 25
3
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Table 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 22520/2-01) . 38
Table A-3 : Guideline for die selection (ferrule coaxial shield crimping) . 38
4
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Foreword
This document (FprEN 16602-70-26:2013) has been prepared by Technical
Committee CEN/CLC/TC 5 “Space”, the secretariat of which is held by DIN
(Germany).
This document (FprEN 16602-70-26:2013) originates from ECSS-Q-ST-70-26C.
This document is currently submitted to the Unique Acceptance Procedure.
This document has been developed to cover specifically space systems and will
the-refore have precedence over any EN covering the same scope but with a
wider do-main of applicability (e.g. : aerospace).
5
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1
Scope
This Standard specifies:
• Requirements for the following crimping wire terminations intended for
high 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 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.
• Product 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 constraints of a
space project, in conformance with ECSS-S-ST-00.
6
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Figure 1-1: Specific interconnections in this Standard
7
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2
Normative references
The following normative documents contain provisions which, through
reference 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 recent 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 - Nonconformance 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
EN 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 for selection of
space materials and processes
MIL-DTL-22520G Crimping tools, terminal hard, wire termination,
general specification for
NASA-STD-8739.4/CHG3 Crimping, Interconnection cables, harnesses and
09/05/2006 wiring
SAE-AS-7928A Terminals, lugs, splices, conductor, crimp style,
02/01/2008 copper, general specification for
SAE-AS-81824 Splices, electric, permanent, crimp style, copper,
08/01/1998 insulated, environment resistant
8
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3
Terms, definitions and abbreviated terms
3.1 Terms defined in other standards
For the purpose of this Standard, 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 tool
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
conductor 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 conductors to each other
3.2.6 terminal
metallic device that is used for making electrical connections
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3.3 Abbreviated terms
For the purpose of this Standard, the abbreviated terms from ECSS-S-ST-00-01
and the following apply:
Abbreviation Meaning
American wire gauge
AWG
quality assurance
QA
process identification document
PID
request for approval
RFA
relative humidity
RH
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4
Principles
This Standard is structured such that the necessary level of quality is achieved
and consistently maintained, and high reliability 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 detail 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 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.
It is important to perform the work taking into account health and safety
regulations, and in particular the national standards on this subject.
11
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5
Requirements
5.1 Preparatory conditions
5.1.1 Facilities
5.1.1.1 Overview
The requirements in this clause can 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
orderly 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 surfaces 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 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 suitably restricted.
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5.1.1.4 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 operation in conformance to MIL-DTL-22520G.
NOTE The mechanism ensures that, once the operation is
started, the tool cannot be opened until the
crimping cycle is complete.
c. Tools shall be marked to show the size and type of termination for which
it is calibrated.
d. Tool calibration shall be verified once each shift in conformance with the
clause 5.5.5 requirements.
e. Proper operation of the integral ratcheting mechanism or the positive
stops on pneumatic tools shall be verified as defined in clause 5.5.6.
f. Before starting a crimping process on a new terminal size and wire type,
tools used for crimping of the previous wire type shall be returned to the
tool facility.
g. If the tool settings seals are broken, the tool shall be returned
immediately for recalibration.
h. Tools used in the crimping operation shall be clean; excess lubricants
shall be removed before crimping starts.
5.1.2.2 Insulation strippers
a. The supplier shall provide the tooling necessary to avoid damage to the
conductor.
b. The selection of thermal or precision cutting devices, manual or
automatic power-driven, shall provide protection of the conductor
strands.
c. Wire stretching by use of mechanical strippers shall be avoided.
d. The conductor shall not be twisted, ringed, nicked, cut or scored by
stripping operation.
e. Both thermal and mechanical stripping tools shall be calibrated
periodically on sample evaluation during a production run.
5.1.2.3 Cutters and pliers
a. The supplier shall provide the tooling necessary for precision wire
trimming and cutting.
13
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b. The cutter used for trimming conductor wire shall shear sharply and
consistently produce a clean, flat, smooth-cut surface along the entire
cutting edge.
c. Twisting action during cutting operation shall be avoided.
d. Smooth, long-nose pliers or tweezers shall be used for attaching or
removing conductor wire.
e. The cutting edges of pliers shall be regularly checked for damage and
maintained in a sharp condition.
5.1.2.4 Test and monitoring equipment
a. The supplier shall provide the equipment specified in Table 5-1 necessary
for verification activities specified in clauses 5.4.2 and 5.4.3.
Table 5-1: Equipment for verification process
Performance tests activity Equipment characteristic
Voltage-drop (in conformance with 0 A - 150 A current source and 0 mV -
clause 5.4.2 requirements) 10 mV voltmeter
Tensile strength (in conformance Tensile testing machine 0 N - 4000 N, accurate to
with clause 5.4.3 requirements) 1 % of full scale load, axial load applied at a rate
of (25 – 50) mm/min ±2 mm/min
Visual inspection Microscope magnification ×7 to ×400
Monitoring requirements of the
process
Temperature 15 °C to 30 °C, accurate to ±1 °C
Relative humidity (RH) 40 % to 70 %, accurate to ±1 %
5.2 Crimping operations for specific interconnections
5.2.1 General
a. The supplier shall visually examine wire, terminal and connector contacts
for cleanliness, absence of oil films and freedom from tarnish or corrosion
before assembly.
b. The supplier shall perform cleaning of the work pieces in conformance
with ECSS-Q-ST-70-08.
c. Further cleaning or other treatment shall not be carried out.
d. The supplier shall handle work pieces with clean lint free gloves or finger
cots.
e. Before a crimping activity, tools at the operator’s station shall be verified
to conform to those selected in accordance with the applicable PID.
f. All conductor strands shall be inserted cleanly into the barrel without
any buckling.
g. Strands shall not be left outside or cut back to reduce the conductor
diameter to fit an undersized barrel.
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h. The supplier shall use tools specified in MIL-DTL-22520.
NOTE Examples of crimping parameters are given in
Table A-2 and Table A-3
i. The supplier shall take provisions to avoid degradation of the silver
plated wire caused by tarnish during storage.
j. In cases when the same wire is joined later by soldering, the solder fluxes
prescribed in ECSS-Q-ST-70-08 shall be used to avoid degradation.
NOTE For shift performance inspection requirements see
clause 5.5.5.
5.2.2 Material selection
a. The supplier shall use silver plated copper multi stranded wire and
braided shield cable in crimp type connectors.
b. Exceptional cases when nickel- or tin-plated wires are used shall be
approved by the customer through a request for approval (RFA), in
conformance with ECSS-Q-ST-70, clause 5.1.4.
c. The supplier shall use high strength copper alloy wire for 24 AWG,
26 AWG and 28 AWG crimped joints.
NOTE Soft or annealed copper wire are not acceptable for
crimped joints of 24 AWG, 26 AWG and 28 AWG
size.
d. The supplier shall use space-qualified components having gold plated
terminals in conformance with ECSS-Q-ST-60.
e. Specific terminals such as ferrules, splices and lugs shall be purchased to
MIL or SAE-AS-7928 specifications.
f. When gold plating is not available the finish shall be in conformance with
ECSS-Q-ST-70-71.
g. Cadmium, chromate-coated cadmium and non-fused tin-plating shall not
be used.
5.2.3 Process review and documentation
a. The supplier shall perform a review of all the materials, tools and
techniques planned to be used to ensure conformance to requirements of
this standard and as a means of identifying potential problems.
NOTE Type of wire includes number of strands, plating
metal, type and thickness of insulation.
b. Dies, setting of controls for the length of strip in automatic stripping
machines and the selection of specific locators or positioners, shall be
selected to meet process requirements.
NOTE The requirement is valid for power driven and
manual crimping processes as well as for size and
tolerance for crimping tools
c. The results of the review shall be documented in a PID in conformance
with DRD of ECSS-Q-ST-70-38.
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5.2.4 Connector barrel and single wire crimping
a. The supplier shall give preference to the selection of single wire
interconnections.
b. The supplier shall not use strands of wire doubled backed to increase the
conductor diameter.
c. The supplier shall use additional stranded wires to increase the cross-
sectional area up to a selected barrel size;
NOTE The requirement is applied for cases where the
insulation is prepared as normal and transparent
“shrink-fit insulation” to cover the loose end of the
wire to prevent any risk of a short circuit.
d. For 28 AWG up to 16 AWG wire sizes, the maximum insulation clearance
shall be equal to the outside diameter (over the insulation) of the wire
being used.
e. The gaps for larger size wires shall not exceed 2 mm.
NOTE No minimum gap is specified except that the
conductor wire shall be visible to permit inspection.
f. Where the terminal or contact is supplied with insulation support, the
wire insulation shall enter the support to the extent that no bare wire is
exposed.
NOTE An example of a typical connector barrel and
single wire crimping is shown Figure 5-1.
Figure 5-1: Example of a typical connector barrel and single wire crimping
5.2.5 Connector barrel and multiple wire crimping
a. Requirements of this clause shall be applied when single wire crimping
cannot be used.
b. The maximum number of wires in one crimp barrel shall be two.
c. The sum of the two nominal conductor sections shall be compatible with
the crimp barrel used
NOTE 2 × 24 AWG is approximately equal to 1 × 20 AWG.
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d. Both conductors shall be of the same material and support the same
plating finish.
NOTE 1 For example: Both are silver and not a combination
of silver and nickel
NOTE 2 Before introduction into the barrel wires or
conductors can be twisted to obtain a “single”
conductor.
e. Axial strength measurements shall be performed on the two associated
wires and the axial strength shall be 75 % of the sum of the two wires
axial strength requirements.
f. For separate conductors introduced into the barrel the following shall
apply:
1. the actual strength measurement is performed on one of the wires
(the smaller, if two different sizes are used);
2. the axial strength requirement is as quoted in Table 5-3 for the
actual size of wire pulled, assuming a barrel size equal to that
wire’s gauge.
NOTE Examples of crimping parameters are given in Table
A-1 and an example of a typical connector barrel and
multi-wire crimping is shown in Figure 5-2.
Figure 5-2: Example of a typical connector barrel and multi-wire crimping
5.2.6 Ferrule shield crimping
a. The shielded wires on coaxial cables shall be braided.
b. Axial strength measurements shall be performed only on the shield after
removal of the core dielectric.
c. Following crimping, the assembly shall be protected by shrink tubing.
NOTE Examples of crimping parameters are given in
Table A-3 and an example of a typical ferrule
shield crimping is shown in Figure 5-3.
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Figure 5-3: Example of a typical ferrule shield crimping
5.2.7 Lug and splice wire crimping
a. Tools specified by the manufacture
...
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