压接钢索的组装ASSEMBLY OF SWAGED CABLES
1. INTRODUCTION 介绍
A. The data in this subject comes from Boeing Process Specification BAC5002. Access to the Boeing Process Specifications is available.
本主题中的数据来自波音工艺规范 BAC5002。可访问波音工艺规范。
B. The data is general. It is not about all situations or specific installations. Use this data to help you write minimum requirements.
数据为通用数据。不适用于所有情况或特定安装。使用这些数据来帮助您编写最低要求。
C. Refer to SOPM 20-00-00 for a full list of all the vendor names and addresses.
有关所有供应商名称和地址的完整列表,请参阅 SOPM 20-00-00。
2. MATERIALS 材料
A. Grease — BMS 3-33 (Replaces BMS 3-24) (Ref SOPM 20-60-03)
润滑脂——BMS 3-33(取代BMS 3-24)(参考SOPM 20-60-03)
B. Oil — Non-detergent, SAE 10W, source optional
油——非清洁剂,SAE 10W,来源可选
C. Barrier material — MIL-B-22191, Type I, II or III
隔离材料——MIL-B-22191,类型I、II或III
D. Tubing, thermal, adhesive — MIL-I-23053/4, Class 2
热粘性油管——MIL-I-23053/4,2级
3. DEFINITIONS 定义
A. One-stage assembly — The cable is completely assembled and given a proof test before it is installed in the airplane. The terminals are installed on each end of the cable at the same time.
单级组件——钢索在安装到飞机上之前已经完成组装并通过验证测试。同时将终端（端子）安装在钢索的两端。
B. Pneumatic swaging — The terminal is swaged on the cable in dies hit with a hammer in a straight line. The terminal is turned slowly in the dies and hit in a fast series with the hammer.
气动压接——用锤子敲击模具,将端子压接在钢索上,使其呈直线。端子在模具中缓慢转动,并用锤子快速敲击。
C. Press swaging — The terminal is compressed between two dies. The terminal is put in the lower die and hit once with a hammer on the upper die. Then the terminal is turned 1/4 turn and hit again. This is continued until the terminal gets to the required size, but with a minimum number of hammer hits.
压接——端子在两个模具之间被压缩。端子放入下模具中,用锤子在上模具上敲击一次。然后将端子旋转1/4圈,再次敲击。如此反复,直到端子达到所需尺寸,但锤击次数最少。
D. Rotary swaging — The terminal is swaged on the cable in dies hit with a hammer around the circumference. The terminal is put into the dies and held there until it gets to the required size.
旋转压接——端子在模具中被锤击,锤击范围是钢索的整个周长。端子放入模具中,直到达到所需尺寸。
E. Two-stage assembly — The cable is assembled in two steps. In the first step, a terminal is installed on only one end of the cable and this assembly is given a proof test. In the second step, the other end is assembled and give a proof test after the cable is installed in the next higher assembly or in the airplane.
两级组件——钢索组件分为两个步骤。第一步,仅将端子安装在钢索的一端,并对该组件进行验证测试。第二步,将钢索安装到下一个更高组件或飞机上,并对另一端进行组装和验证测试。
4. CALCULATION OF CABLE LENGTH 钢索长度的计算
A. The total length of the cable after assembly and the test will be longer than the lengths of the terminals and the cable before they are assembled. The terminals will be longer after they are swaged, and the cable will be longer after the proof test. Make sure you include an allowance for each of these changes before you cut the cable to the required length. See Figure 1 for details.
组装和测试后的钢索总长度将比端子和钢索组装前的长度长。端子在压接后会变长,钢索在验证测试后会变长。在将钢索剪到所需长度之前,请确保考虑了这些变化。详情请参阅图1。
B. In the two-stage assembly procedure, do the assembly and proof test at the first end of the cable. Then measure the length of the cable to the location where the other end will be. Make a reference mark here, or cut the cable to a length which is a known amount longer than the required length. After you install the cable, use the mark or remove the known amount before you swage the terminal on the second end of the cable.
在两级组装程序中,先在钢索的一端进行组装和验证测试。然后测量钢索到另一端位置的长度。在此处做一个参考标记,或者将钢索剪到比所需长度长出已知长度的长度。安装钢索后,在钢索另一端的端子压接前,使用标记或去除已知长度。
C. When you cut the cable wire rope, make sure the cut is clean and the strands do not wind off or come apart.
切割钢丝绳时,确保切口干净,绳股不会缠绕或散开。
5. ASSEMBLY OF THE PIECES 片的组装
A. If the wire rope has a nylon jacket, remove the nylon from the end of the wire rope before you put the rope in the terminal. Remove a length of nylon to give 1/2 inch maximum clearance between the terminal and the jacket after the rope is installed in the terminal.
如果钢丝绳有尼龙护套,在将绳索放入端子前,先从绳索末端去除尼龙。去除一段尼龙,使绳索安装到端子后,端子与护套之间留有最大1/2英寸的间隙。
B. Put the cut end of the wire rope into the bore of the terminal, down to the full depth of the bore.
将钢丝绳的切端放入端子孔中,直至完全插入。
C. If the bore of the terminal does not go completely through, make sure the wire rope is at the full depth by one of these procedures:
如果端子孔没有完全插入,请通过以下方法之一确保钢丝绳完全插入:
(1) Measure the depth of the bore. Mark this as a length from the end of the wire rope before you install and swage the terminal.
测量孔的深度。在安装和压接端子前,标记从钢丝绳末端开始的长度。
(2) Use an approved nondestructive procedure after you do the proof test.
在进行验证测试后,使用经认可的无损检测程序。
D. Terminals can be staked on the wire rope to keep them in the correct position before they are swaged. After swaging, the depth of this stake must be a maximum of 0.003 inch. The stake must be within the minimum swage length given by Paragraph 6.F. below.
在压接前,可将端子固定在钢丝绳上,以保持其正确位置。压接后,该固定物的深度不得超过 0.003 英寸。该固定物必须位于下文第 6.F 段规定的最小压接长度范围内。
E. If this cable assembly will be part marked with a heat-shrink tube, be sure to put the tube on the cable before you install the terminal. Refer to Paragraph 8. for more information about identification.
如果该钢索组件的零件上标有热缩管,请务必在安装端子前将热缩管套在钢索上。有关识别的更多信息,请参阅第8段。
6. SWAGING 压接
A. You can use rotary swaging, press swaging, or pneumatic swaging. These procedures are compared in Paragraph 3.
您可以使用旋转压接、压力压接或气动压接。第3段对这些程序进行了比较。
B. The swaging must smoothly cold-work the terminal until its dimensions agree with the data given by Paragraph 6.F.
压接必须使端子顺利冷加工,直到其尺寸符合第6.F段给出的数据。
C. During the swaging procedure, do not let the die touch the hex, the fork, or the eye of the terminal.
在压接过程中,不要让模具接触端子的六角、叉形端或孔眼。
D. You can use BMS 3-33 grease or SAE 10W oil to prevent damage to the terminals or the dies.
可以使用BMS 3-33润滑脂或SAE 10W油,以防止损坏端子或模具。
E. Do not swage the same terminal a second time, or soak it while it is in the dies.
不要对同一个端子进行第二次压接,或在磨具中时将其浸泡。
F. After the swage, the terminals must agree with:
压接后,端子必须符合以下要求:
(1) The applicable MS or BAC part standard, for the ball end and cylindrical terminals
球形端子和圆柱形端子符合适用的 MS 或 BAC 零件标准
(2) Figure 2 for MIL-T-781 standard terminals.
图2为MIL-T-781标准端子。
G. The swaged terminal must have no pits, die marks, cracks that could be seen with a 10-power lens, or other surface defects caused by the swage procedure. Small nicks or dents are satisfactory if the swaged surface is 63 microinches or smoother.
压接端子不得有凹坑、模痕、10倍放大镜能看到的裂纹,或因压接工艺造成的其他表面缺陷。如果压接表面光滑度达到63微英寸或更好,则小刻痕或凹痕是可以接受的。
H. The threaded, eye, or fork end of the terminal must be straight with the centerline of the swaged end as shown in Figure 3. Do not try to bend a swaged terminal which is not straight.
端子的螺纹、孔眼或叉形端必须与压接端中心线保持笔直,如图3所示。请勿尝试弯曲不直的压接端子。
I. The length of the swaged cable assembly must agree with the required length when measured under these loads:
在以下负载下测量时,压接钢索组件的长度必须与所需长度一致:
(1) 17-23 pounds, for cables with wire rope diameter (without the nylon jacket) of 3/32 inch or smaller
17-23 磅,适用于钢丝绳直径(不含尼龙护套)为 3/32 英寸或更小的钢索
(2) 37-43 pounds, for cables with wire rope diameter (without the nylon jacket) of more than 3/32 inch.
37-43 磅,适用于钢丝绳直径(不含尼龙护套)大于 3/32 英寸的钢索。
J. The cable assembly must not have kinks, a damaged nylon jacket, popped cores, broken wire strands, or wire ends above the terminal ends.
钢索组件不得有扭结、尼龙护套损坏、芯线弹出、线股断裂或超出端子端的线头。
7. PROOF TEST 验证测试
A. Do a proof test on each cable assembly. Use the loads given by Figure 4. These loads are 60 percent of the load which will break the cable. Apply the load, smoothly and gradually, by a dead load or a test machine in not less than 3 seconds. Hold the load for a minimum of 5 seconds. Release the load smoothly and gradually.
对每个钢索组件进行验证测试。使用图4给出的载荷。这些载荷是使钢索断裂的载荷的60%。通过静载荷或测试机器平稳、逐渐施加载荷,持续时间不少于3秒。保持载荷至少5秒。平稳、逐渐释放载荷。
B. During the test, the terminals must not move along the cable. To see if the terminal moves, mark the cable before the test, or use an approved nondestructive procedure after the test.
在测试过程中,端子不得沿钢索移动。为了检查端子是否移动,可在测试前在钢索上做标记,或在测试后使用经认可的无损检测程序。
C. The cable surface or jacket must not be damaged if it is held by the load during the proof test.
在验证测试期间,如果钢索表面或护套被负载固定,则不得损坏。
8. IDENTIFICATION 标识
A. If the cable assembly has MS20658, MS20667, MS20668, MS21259, or MS21260 terminals, or a terminal with a swaged surface area the same or larger than a MS21259-3 terminal, permanently mark it as specified in Paragraph 8.B. Temporarily mark all other cable assemblies as specified in Paragraph 8.C.
如果钢索组件带有 MS20658、MS20667、MS20668、MS21259 或 MS21260 端子,或者带有压接表面积与 MS21259-3 端子相同或更大的端子,则应按照第 8.B 段的规定进行永久标记。按照第 8.C 段的规定对所有其他钢索组件进行临时标记。
B. Permanent Identification
永久标识
NOTE: You can mark with electrochemical etch as specified in Paragraph 8.B.(1) before you swage, or install a hot-stamped heat-shrink tube as specified in Paragraph 8.B.(2) after you swage that terminal on the cable.
注意:您可以在压接前按照第8.B.(1)段的规定进行电化学蚀刻标记,也可以在将端子压接在钢索上后按照第8.B.(2)段的规定安装热缩管。
(1) Electrochemical Etch — Before you swage the terminal on the cable, etch the part number and other important data on the shank as specified in SOPM 20-50-10 and Figure 5.
电化学蚀刻——在将端子压接至钢索上之前,按照SOPM 20-50-10和图5的规定,在柄部蚀刻件号和其他重要数据。
(2) Hot-Stamped Heat-Shrink Tube
热印热缩管
(a) Get the correct heat-shrink tube for the cable diameter as specified in Figure 5.
按照图5的规定,为钢索直径选择正确的热缩管。
(b) Hot-stamp the tubing as specified in BAC5152 with the part number and other important data.
按照 BAC5152 中的规定,在管子上烫印件号和其他重要数据。
(c) Wipe the shank of the terminal with solvent. Be careful not to remove lubricant from the cable.
用溶剂擦拭端子的柄部。注意不要将钢索上的润滑剂去除。
(d) Put the marked tube on the shank of the terminal as shown in Figure 5. Shrink the tube with a hot-air gun at 500°F.
如图 5 所示,将标记的热缩管放在端子的柄部上。用热风枪在 500°F下使热缩管收缩.
C. Temporary Identification
临时标识
(1) Use temporary marking if permanent marking is not immediately possible.
如果无法立即进行永久性标记,请使用临时标记。
(2) Put a tag or tape on the cable as shown in Figure 5. Print, type, or stamp the part number and other important data (such as the vendor data) on the tag or the tape.
如图 5 所示,在钢索上贴上标签或胶带。在标签或胶带上印刷、打印或盖上件号和其他重要数据(例如供应商数据)。
9. PROTECTION 保护
A. Apply BMS 3-33 grease as specified in SOPM 20-50-07 to all carbon steel wire rope that does not have a jacket, to lubricate and prevent corrosion. Do not apply grease to CRES wire rope.
根据SOPM 20-50-07的规定,在所有没有护套的碳钢钢丝绳上涂抹BMS 3-33润滑脂,以润滑和防止腐蚀。不要在CRES钢丝绳上涂抹润滑脂。
B. When you put the cables into storage, keep them straight, or put them in coils no smaller than the diameters of Table 1.
将钢索进行存储时,应保持其笔直,或将其卷入不小于表1中直径的线圈中。
(1) Put the coils of cable in standard bags or bags made of MIL-PRF-22191 barrier materials. Close the bags with a heat seal, or fold and staple them closed.
将钢索放入标准包装袋或由MIL-PRF-22191阻隔材料制成的包装袋中。用热封或折叠和订书钉将袋子密封。
(2) If the cable has a metal-clad area that is more than 12 inches longer than the coil diameter, put only the coils in the bag. If the metal-clad area is shorter than this, put all of the cable assembly in one bag.
如果钢索的金属包层区域比线圈直径长12英寸以上,则只将线圈放入袋子中。如果金属包层区域比线圈直径短,则将钢索组件全部放入一个袋子中。
