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1、 AEROSPACE STANDARD AMENDMENT Terminal Junction System (TJS), Environment Resistant General Specification For SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, a
2、nd its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written c
3、omments and suggestions. Copyright 2004 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission
4、of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA) Fax: 724-776-0790 Email: custsvcsae.org SAE WEB ADDRESS: http:/www.sae.org Issued 2004-06 AS81714-A1 1. Present Requirement: 2.1 Government documents, Page 10 MIL-STD-105 Sampling Procedures
5、5 for size 16; and 3 for size 12. 4.4.2.4End seal plugs: Ten MS27488 end seal plugs for each contact size tested by the applicant shall be furnished to the qualification activity. The plugs shall represent the part which will be provided by the applicant on procurement contracts. 4.4.3Qualification
6、failure: Any failures during examination or tests specified in Tables IV shall be reported to the qualification activity before continuing testing. Based on corrective action, authorization to complete the qualification tests will be granted. The applicants products shall pass all requirements of th
7、is specification. 4.4.4Assembly plants: To furnish products under this specification (3.2), assembly plants must be listed on, or approved for listing on, the applicable Qualified Products List. The qualified terminal junction system supplier shall certify that the assembly plant is approved for ass
8、embly and distribution of the suppliers parts. The assembly plant shall use only piece parts supplied by the qualified terminal junction system manufacturer. Qualification requirements will be dependent upon the type of assembly performed by the assembly plant. All assemblies produced at the assembl
9、y plant shall be subjected to the quality assurance provisions specified herein. Quality control requirements, including Government inspection surveillance, shall be the same as required for the qualified terminal junction system manufacturer. 4.5Quality conformance inspection: 4.5.1Inspection of pr
10、oduct for delivery: Inspection of product for delivery shall consist of Groups A and B. 4.5.1.1Inspection lot: An inspection lot, as far as practicable, shall consist of terminal junction components covered by one specification sheet, produced under essentially the same conditions, and offered for i
11、nspection at one time. -,-,- SAE AS81714 - 27 - 4.5.1.2Disposition of sample units: Sample units which have been subjected to the Group A inspection may be delivered on the contract or order. Sample units which have been subjected to the Groups B and C inspection shall not be delivered on the contra
12、ct or order. 4.5.1.3Group A inspection: Group A inspection shall consist of the examinations and tests specified in Table V and shall be made on the same set of sample units in the order shown. In-process control of component parts, unrelated to lot sizes of finished terminal junction assemblies, ma
13、y be used in lieu of examination and test of these components in the finished terminal junction assemblies to assure performance of these component parts. TABLE V. Group A inspection. 4.5.1.3.1Sampling plan: Statistical sampling and inspection shall be in accordance with MIL-STD-105 for general insp
14、ection Level II. The acceptable quality level (AQL) shall be 1.0 for major and 4.0 for minor defects. 4.5.1.4Group B inspection: Group B inspection shall consist of the examinations and tests shown in Table VI, performed in the order shown, and shall be made on sample units which have passed the Gro
15、up A inspection. SAE AS81714 - 28 - TABLE VI. Group B inspection. 4.5.1.4.1Sampling plan: The sampling plan shall be in accordance with MIL-STD-105, inspection level S-3 and the AQL shall be 4.0. 4.5.1.5Group C inspection: Group C inspection for periodic verification of quality shall consist of all
16、the examinations and tests specified in Table VII. Shipment shall not be held up pending results of this inspection. 4.5.1.5.1Sampling plan: The number of samples required for Group C inspection shall be the same as required for qualification (4.4.1). 4.5.1.5.2Retention of qualification: a.In order
17、to retain qualification, a summary of Group C test results (see 4.5.1.5) shall be furnished to the Qualification Activity at 24-month intervals and shall include summary results of Groups A and B tests performed during that period. The summary shall also include the number and type of any part failu
18、res. Failure to furnish the summary shall result in loss of qualification for that product. The qualified source shall request authorization to begin retention of qualification. b.Any failures during Group C testing shall be reported immediately to the Qualification Activity. Authorization to comple
19、te Group C tests will be based on acceptance of the corrective action. c.To retain qualification the applicants products shall pass all requirements of Groups A, B and C tests. 4.5.2Inspection of preparation for delivery: Sample packages and packs and the inspection of the preservation-packaging, pa
20、cking and marking for shipment and storage shall be in accordance with requirements of Section 5 and the documents specified therein. SAE AS81714 - 29 - TABLE VII. Group C periodic tests. -,-,- SAE AS81714 - 30 - 4.6Methods of examination and test: 4.6.1Visual and mechanical: TJS components shall be
21、 examined to insure conformance with this specification and the applicable specification sheet. For Group A inspection, in-process control of component parts, unrelated to lot sizes of finished items, may be utilized in lieu of examination of these component parts. Examination in a continuing manner
22、 shall be performed to assure compliance with the following requirements: a.Applicable military specification sheet (3.1) b.Materials(3.3) c.Design and construction(3.4) d.Marking(3.6) e.Workmanship(3.7) 4.6.2Probe damage (Series I): Items subjected to this test shall have the wire sealing member re
23、moved. The housing containing the internal contacts shall be held its full length in such a manner that the axis of the internal contacts shall be horizontal throughout the test. A minimum of four internal contacts shall be tested, each at three different depths, as follows: a.Full insertion depth b
24、.Full insertion minus 0.040 .003 inch c.Full insertion minus 0.110 .003 inch The test probe for each contact size shall comply with Figure 1. The test probes shall be inserted into the internal contact to the specified depth, and the applicable bending moment, selected from Figure 1, shall be applie
25、d to the test probe, perpendicular to the major axis of the contact. With the bending moment force applied, the internal contact shall be rotated 360 by turning the housing in the plane perpendicular to the horizontal axis of the probe. This test shall be repeated for each insertion depth required.
26、Following the probe test, the internal contacts shall comply with contact resistance (3.5.16) and low signal contact resistance (3.5.17) (3.5.1). SAE AS81714 - 31 - FIGURE 1. Test probe. 4.6.3Maintenance aging (except racks and brackets): Inserting and removal of a contact shall be considered one cy
27、cle. For qualification only, all cavities shall be considered one cycle. For qualification only, all cavities shall be subjected to one cycle of inserting and removal. A minimum of 20 percent, but not less than 3 contacts, shall be then subjected to nine additional cycles of inserting and removal, u
28、sing the specified military tools. The contact inserting and removal forces (3.5.3) shall be measured during the first and tenth cycle as specified in Table VIII (3.5.2). SAE AS81714 - 32 - TABLE VIII. Contact insertion and removal forces. 4.6.4Contact retention: Contact retention shall be tested in
29、 accordance with MIL-STD-1344, Method 2007, under the tensile load of Table IX. TABLE IX. Axial tension loads for contact retention. SAE AS81714 - 33 - 4.6.5Thermal shock: Wired components shall be tested in accordance with MIL-STD-1344, Method 1003, Test Condition A except applying temperature extr
30、emes in Table X in lieu of steps 1 and 3. Components shall be mounted in racks. Following the fifth cycle, with the ambient temperature reduced to -15C, a minimum of three contacts shall be mated and unmated five times. Electrical continuity shall be determined at the low and high temperature extrem
31、es. Insulation resistance at ambient temperature shall be measured at the completion of the final cycle. TABLE X. Temperature extremes. 4.6.6Dielectric withstanding voltage: 4.6.6.1Dielectric withstanding voltage, sea level: Wire components shall be tested in accordance with Method 3001 of MIL-STD-1
32、344, Test Condition I. The applicable test voltages of Table XI shall be applied between all adjacent contacts not common and between the housing and each contact closest to the housing and the rack. Blocks shall be mounted in a rack during this test and the conductive plated or unplated rack shall
33、be connected to one test lead of the transformer during the housing/contact phase of the test. In-line junctions shall be closely wrapped in metal foil which shall be connected to one test lead of the transformer (3.5.6). 4.6.6.2Dielectric withstanding voltage (DWV), altitude: Wired components shall
34、 be tested in accordance with Method 3001, Test Condition IV, MIL-STD-1344. After 30 minutes at the simulated altitude, the samples shall be tested as specified in 4.6.6.1 (3.5.6). SAE AS81714 - 34 - TABLE XI. DWV test voltages. (These are not working voltages) 4.6.7Fluid immersion: Components shall
35、 be subjected to fluids in accordance with Method 1016 of MIL-STD-1344 and Table XII. Safety precautions shall be taken for flammable fluids when performing electrical requirements after fluid immersion (3.5.7). TABLE XII. Test fluids. SAE AS81714 - 35 - 4.6.8Vibration: 4.6.8.1Sine vibration: TJS co
36、mponents shall be subjected to the test specified in Method 204, Test Condition G, of MIL-STD-202. Duration of vibration at specified temperatures shall be as follows: a.4 hours at -50C. b.4 hours at +200C. c.4 hours at ambient temperature. 4.6.8.2Random vibration: TJS components shall be subjected
37、to the test specified in Method 2005 of MIL-STD-1344. The following details shall apply: a.Test Condition VI - Letter “J” at ambient temperature. b.Vibration shall be performed at ambient temperature. c.Duration shall be 8 hours in the longitudinal direction and 8 hours in a perpendicular direction
38、for a total of 16 hours. 4.6.8.3Block mounting: The blocks shall be mounted in racks or brackets during the vibration test. The rack shall have a minimum of two and a maximum of X-1 blocks, where X represents the maximum number of blocks accommodated by the rack. The rack or bracket shall be firmly
39、attached to the vibration table. A suitable sensor shall monitor the vibration of the block(s) at a point near the blocks. The wire bundles shall be clamped to nonvibrating points a minimum of eight inches from the blocks. Feed through blocks shall be wired at both faces. The clamping length of the
40、wires shall be chosen to avoid resonance of the wire bundles. 4.6.8.4In-line junction mounting: In-line junctions shall be firmly attached to the vibration table. A suitable sensor shall monitor the vibration at a point near the junctions. The wires shall be clamped to nonvibrating members a minimum
41、 of eight inches from the junctions, and the clamping length of the wires shall be chosen to avoid resonance of the wires. 4.6.9Mechanical shock: Wired components shall be subjected to the test specified in Method 2004 of MIL-STD-1344. Components shall be mounted by normal means, with 100 milliamper
42、es maximum current flow through the series circuit during shock. Components shall be monitored for any discontinuities. A detector capable of detecting all discontinuities in excess of 1 microsecond shall be used. The following details shall apply: a.Test condition D. b.The wire bundle shall be clam
43、ped to fixed points at least 8 inches from the rear of the TJS component. SAE AS81714 - 36 - 4.6.10 Humidity: TJS components shall be subjected to the humidity test specified in Method 1002, Type II, omitting subcycle step 7b of MIL-STD-1344. The following details and exceptions shall apply: a.Step
44、7a shall be performed during the last cycle. b.Three hours minimum after the start of step 7a, during the final cycle and while the devices are still subjected to high humidity, the insulation resistance (4.6.11) shall be measured when the chamber temperature reaches 20 5C and condensation is observ
45、ed on the devices. 4.6.11 Insulation resistance: An insulation resistance measurement in accordance with Method 3003 of MIL-STD-1344 (3.5.11) shall be made on wired blocks mounted in an unplated or plated conductive aluminum rack. The resistance shall be measured between all but not more than three
46、pairs of adjacent contacts which are not common and between all but not more than six contacts closest to the housing and the rack. For in-line junctions, the resistance shall be measured between the conductor of the wire and metallic foil wrapped around the main body of the junction (3.5.11.1). Sim
47、ulated contacts may be used for performing this test, in lieu of actual contacts. Any other variations from specified procedures shall be approved by the qualifying activity. 4.6.11.1 Insulation resistance at room condition: When tested at room condition, the component shall meet the requirement of
48、3.5.11.1. 4.6.11.2 Insulation resistance at elevated temperature: When tested at elevated temperatures, the component shall meet the requirements of 3.5.11.2. The measurement shall be made at the end of the temperature life test (4.6.13) while the devices are at elevated temperature. 4.6.12 Salt spr
49、ay (corrosion): TJS components shall be subjected to a salt spray test in accordance with Method 1001, Test Condition C, MIL-STD-1344. The salt concentration shall be five percent. The specimens shall then be dried in a circulating air oven at a temperature of 38C 3C (100F 5F) for a period 12 hours maximum, after which they shall be removed (blocks shall be taken out of the racks) and inspected. Wiring type components s