BS 5G 178-1

Provides updated tests and test requirements for crimped joints with copper, copper alloy, aluminium and aluminium alloy conductors. Aircraft components, Space technology components, Crimped connectors, Electric connectors, Electric wires, Electrical connections, Electric conductors, Electric cables, Electrical components, Electric terminals, Mechanical crimping, Crimping tools, Design, Marking, Performance, Performance testing, Testing conditions, Specimen preparation, Type testing, Electrical testing, Thermal-cycling tests, Tensile testing, Mechanical testing, Chemical-resistance tests, Heat ageing tests, Dielectric-strength tests, Low-temperature testing, Low-pressure tests, Dimensions

Standards

Featured or equivalent test standards for Mecmesin solutions in this section

Crimped joints for aircraft electrical cables and wires. Specification for design requirements (including tests) for components and tools

Term Video

Test summary

This Part of BS 5G 178 specifies the design requirements and tests for components and tools for the crimping of insulated and non-insulated terminals and splices to general purpose electrical cables or equipment wires for aircraft with conductors of copper, copper alloy, aluminium or aluminium alloy, in locations in which the stabilized conductor temperature does not exceed the value specified for the relevant type of cable.

The standard prescribes a series of tests to be performed in a defined sequence. These include:

Visual inspection of tooling, connectors and completed joints in correspondence with approved drawings.

Voltage drop test

Salt spray test

Load and temperature cycling

Tensile test

Test method

The tensile load test may be performed on its own or as part of the full range of test which should be conducted in the order given in the standard. Sufficient quantities of crimped joint should be made to fulfil the minimum number of replicates for the entire test sequence as planned.

Visually inspect the conductors, crimps and tooling to ensue all are in accord with their relevant approved drawings.

Form the crimped connection as detailed in the standard and in according to the manufactures instructions.

Follow the sequence of testing given with the prescribed number of test specimens for each stage.

For the tensile test, note the instruction to render the insulation support ineffective if this is required.

Test each sample by loading into the jaws/receptacle of the motorised tester and pulling the joint to destruction at a steady rate of 25 – 50 mm/min. Check that the pull-off load does not fall below the minimum values given in the standard.