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1、BRITISH STANDARD AEROSPACE SERIES BS G 235:1987 Specification for Electric cables for general airframe or equipment interconnect use (150 C), wrapped insulation with silver plated conductors UDC 629.7.064.5:621.315.33-408.4 Licensed Copy: London South Bank University, London South Bank University, S
2、at Dec 09 02:31:34 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 235:1987 This British Standard, having been prepared under the direction of the Aerospace Standards Committee, was published under the authority of the Board of BSI and comes into effect on 30 September 1987 BSI 01-2000 The following
3、 BSI references relate to the work on this standard: Committee reference ACE/6 Draft for comment 85/71992 DC ISBN 0 580 15921 3 Committees responsible for this British Standard The preparation of this British Standard was entrusted by the Aerospace Standards Committee (ACE/-) to Technical Committee
4、ACE/6, upon which the following bodies were represented: BEAMA Ltd. British Airways British Rubber Manufacturers Association Civil Aviation Authority Electric Cable Makers Confederation Electronic Components Industry Federation Ministry of Defence National Supervising Inspectorate Society of British
5、 Aerospace Companies Limited Amendments issued since publication Amd. No.Date of issueComments Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:31:34 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 235:1987 BSI 01-2000i Contents Page Committees responsibleInsi
6、de front cover Forewordii 1Scope1 2Classification1 3Construction1 4Designation and marking2 5Packaging and labelling2 6Tests2 7Reference samples6 Figure 1 Variation of resistance of copper with temperature16 Table 1 Type 01, class 1: single-core unscreened interconnect cables (150 C)6 Table 2 Type 0
7、2, class 1: single-core unscreened airframe cables (150 C)7 Table 3 Type 01, classes 2, 3 and 4: multi-core unscreened, twisted interconnect cables without jacket (150 C)7 Table 4 Type 02, classes 2, 3 and 4: multi-core unscreened, twisted airframe cables without jacket (150 C)8 Table 5 Type 03, cla
8、sses 2, 3 and 4: multi-core unscreened, twisted interconnect cables with jacket (150 C)8 Table 6 Type 04, classes 2, 3 and 4: multi-core unscreened, twisted airframe cables with jacket (150 C)8 Table 7 Type 05, classes 1, 2, 3 and 4: single-core screened with jacket, and multi-core twisted and scree
9、ned with jacket, interconnect cables (150 C)9 Table 8 Type 06, classes 1, 2, 3 and 4: single-core screened with jacket, and multi-core twisted and screened with jacket, airframe cables (150 C)10 Table 9 Test application11 Table 10 Specific test parameters13 Table 11 Current ratings in amperes for ge
10、neral purpose 150 C airframe cable15 Publications referred toInside back cover Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:31:34 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 235:1987 ii BSI 01-2000 Foreword This British Standard, having been prepared u
11、nder the direction of the Aerospace Standards Committee, specifies requirements for a range of lightweight thin-wall insulated cables that are individually suitable for general airframe or equipment interconnect use. The dielectric insulation material is spirally lapped with an overall coating to pr
12、ovide the necessary colour coding and to provide a base for printed identification legends. The standard requires the application of the dielectric material so as to provide the minimum penalties of weight and space whilst offering reliable performance over a full airframe life of not less than 50 0
13、00 h. Cables manufactured to this standard are not required to meet the fire resistance requirements of BS 3G 100:Subsection 3.13 but they are required to satisfy the flammability requirements of BS G 230. Attention is drawn to BS G 230 which specifies the general requirements for aircraft electric
14、cables (second series). A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages
15、This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 16, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. L
16、icensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:31:34 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 235:1987 BSI 01-20001 1 Scope This British Standard specifies construction and performance requirements for a range of lightweight cables with wrapped insulat
17、ion and silver plated conductors suitable for general airframe use in the size range 26 to 0000, and for equipment interconnect in the size range 26 to 18. The following types of cable are specified: The cables are suitable for continuous use where the maximum stabilized conductor temperature does n
18、ot exceed 150 C. They are suitable for applications involving flexing at temperatures down to 65 C. The cables are suitable for use where the potential between conductors or between a conductor and screen, or the aircraft structure does not exceed 600 V r.m.s. and the frequency does not exceed 2 000
19、 Hz. Interconnect cables are suitable for use in areas with some physical protection, such as behind panels or bulkheads, They also have an application for the internal wiring of equipment. Airframe cables are of sufficiently robust construction to be used for open aircraft wiring. The short-term an
20、d long term current ratings for the cables are specified in this standard. NOTEThe titles of the publications referred to in this standard are listed on the inside back cover. 2 Classification Cables are classified according to the number of cores as follows: 3 Construction 3.1 General The materials
21、 and method of construction used for the formation of the cables shall be defined and controlled to the satisfaction of the Approving Authority1). No change shall be made to such materials or processes unless it can be shown to the satisfaction of the Approving Authority that the performance and han
22、dling properties of the cable have not been degraded. The cable shall be made of materials such that the performance requirements of this standard are satisfied. 3.2 Conductors 3.2.1 Conductors shall comply with BS G 231 before fabricating into completed cables. 3.2.2 Copper strands and copper alloy
23、 strands shall be silver plated. 3.3 Insulation The insulation for interconnect cables shall consist of one or more overlapped tapes of insulating material, and for airframe cables, two or more overlapped tapes. An overall coating may also be provided which, for the purposes of this standard, shall
24、be regarded as part of the cable. The insulating material shall be such that the performance requirements of this standard are satisfied. Only 100 % new materials that have been through only those processes essential to their manufacture and application shall be used. Type 01 interconnectSingle-core
25、 or twisted multi-cores only Type 02 airframe Type 03 interconnectTwo or more cores, with an outer jacket Type 04 airframe Type 05 interconnectSingle- or multi-core, with a screen and outer jacket Type 06 airframe class 1: single core class 2: two core class 3: three core class 4: four core 1) The A
26、pproving Authority is either: a) for UK Civil Aviation products, the Civil Aviation Authority (or their accredited representatives); or b) for UK military products, information is available from the Procurement Executive, Ministry of Defence, Directorate General of Defence Quality Assurance, Directo
27、rate of Standardization, Kentigern House, 65 Brown Street, Glasgow G2 8EX. Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:31:34 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 235:1987 2 BSI 01-2000 3.4 Screen The screen shall be constructed of a braid havin
28、g a coverage of 85 % minimum, and a lay factor less than 3 when calculated in accordance with Appendix A of BS G 230. There shall be no joints in the complete screen. Where breaks in individual strands occur, the ends shall be brazed or tucked into the weave ensuring that the cut end is on the outsi
29、de of the screen. There shall be not more than one such break in any 300 mm length of cable or in any 10 m length of individual strand. Strands from which the braid is constructed shall be silver plated and comply with BS G 231 before braiding. 3.5 Jacket The jacket shall be made of insulating mater
30、ial, and shall be constructed, such that the performance requirements of this standard are satisfied. 3.6 Single-core cables The mass and dimensions of single-core cables shall be as given in Table 1 and Table 2 as appropriate. 3.7 Multi-core cables The mass and dimensions of multi-core cables shall
31、 be as given in Table 3 to Table 8 as appropriate. The cables shall consist of two or more single cores complying with 3.6, twisted together with a lay of approximately 12 times the pitch circle diameter for sizes 26 to 4 and approximately 16 times the pitch circle diameter for sizes 2 to 0000. Type
32、s 01 and 02 shall consist of twisted assemblies of single-core cable, types 03 and 04 of twisted assemblies with an outer jacket, and types 05 and 06 of twisted assemblies with a screen and outer jacket. 3.8 Colour The colour of the insulation for class 1 cables, the core insulation for multi-core c
33、ables and the jackets shall comply with BS G 230. 4 Designation and marking 4.1 Manufacturers marking and designation The designation and marking of the cables shall be in accordance with BS G 230. 4.2 User applied marking 4.2.1 The surface of the insulation or coating of type 02 (airframe) cable sh
34、all be suitable for the acceptance of user applied identification marks by at least one of the following methods: a) hot stamp marking; b) laser marking; c) ink jet. The cable manufacturer shall declare which method is suitable and the tests given in clause 6 shall be performed using cables that hav
35、e been so marked. 4.2.2 Appropriate methods of marking the outer jacket of cable types 03, 04, 05 and 06 shall be declared by the manufacturer who may specifically prohibit the use of hot stamp or laser marking. 4.2.3 Type 01 (interconnect) cable shall not be required to accept hot stamp or laser ma
36、rkings or any other method that may degrade the insulation material. 5 Packaging and labelling The cables shall be packaged and labelled in accordance with BS G 230. 6 Tests The following tests shall be carried out in accordance with BS G 230. Specific requirements of this standard are given against
37、 the appropriate test. The application of each test for qualification approval, production quality testing, inspection lot testing and production routine testing shall be as given in Table 9. All qualification approval test specimens shall be marked in accordance with clause 4 before commencement of
38、 testing. Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:31:34 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 235:1987 BSI 01-20003 NOTEFor qualification approval testing, specimens selected from a particular size within the following groups may be consider
39、ed as proving the requirements for all sizes within that group of a given type (see clause 1). Qualification of type 05 cable may be considered as proving the requirements of type 03, classes 2 to 4, and type 06 as proving type 04, classes 2 to 4. Group 1. Sizes 26 to 24, type 02, classes 1 to 4 Gro
40、up 2. Sizes 22 to 16, type 02, classes 1 to 4 Group 3. Sizes 14 to 10, type 02, class 1 Group 4. Sizes 8 to 2, type 02, class 1 Group 5. Sizes 1 to 0000, type 02, class 1 Group 6. Sizes 26 to 24, type 01, classes 1 to 4 Group 7. Sizes 22 to 18, type 01, classes 1 to 4 Group 8. Sizes 26 to 16, type 0
41、6, classes 1 to 4 Group 9. Sizes 26 to 18, type 05, classes 1 to 4 BS G 230 test no. Test applicable to cable types 01 and 02 Specific requirements of this standard 1. 2. 3. 4. 5. 6. 7. Appearance and identification of finished cable Mass per unit length of finished cable Conductor composition Visua
42、l examination of strands Insulation thickness and concentricity Core and cable outer diameters Tensile strength and elongation at break of copper or copper alloy conductors Maximum values shall be as given in Table 1 to Table 6 Minimum values shall be as given in Table 1 and Table 2 Minimum and maxi
43、mum values shall be as given in Table 1 to Table 6 Values shall be as follows: Strand diameter Tensile strengthElongation Min.Max.Min. mm Copper alloy 0.08 to 0.12 N/mm2 350 (for 7 strands) N/mm2 % 6 Copper 0.08 to 0.12 0.15 to 0.45 220 220 300 300 9 10 9. 10. 11. 12. 14. 14(a). 14(b). 15. 16. 16(a)
44、. 16(b).a 16(c).a Strand plating continuity Strand plating adherence Strand plating thickness Electrical resistance of conductor Solderability Method 1 Method 2 Conductor strand adhesion High voltage Immersion Dry spark Dry impulse Maximum values shall be as given in Table 1 to Table 6 This test sha
45、ll be carried out on sizes 20 to 26 only. Use non-activated flux complying with 4.6.2 of BS 2011-2.1T:1981 and solder of grade KP of BS 219. Solder bath temperature 235 3 C. Wetting time 1.0 s 2 500 75 V r.m.s. 5 000 150 V r.m.s. 8 000 250 V peak a Either test 16(b) or 16(c) may be carried out. Lice
46、nsed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:31:34 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS G 235:1987 4 BSI 01-2000 BS G 230 test no. Test applicable to cable types 01 and 02 Specific requirements of this standard 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
47、27. 28. 28(a). 28(b). 29. 30. 31. 32. 35. Insulation resistance Surface resistance Accelerated ageing Thermal endurance Adherence of insulation on conductor Delamination and shrinkage Delamination and insulation blocking Room temperature bend Cold bend Dynamic cut-through Notch propagation resistanc
48、e Flammability Method 1 Method 2 Resistance to fluids Scrape abrasion Overload resistance Delamination Climatic Test temperature 200 2 C. Time 168 h. Mandrel diameter and force shall be as given in Table 10 50 000 h minimum at 150 2 C Minimum adherence forces shall be as given in Table 10 Five cycle
49、s from room temperature to 150 2 C holding the top temperature for 1 h and allowing the cable to return to room temperature between cycles. Maximum length of conductor exposed at each end is 1.0 mm for sizes 26 to 10, and one-quarter maximum outside diameter for sizes 8 to 0000 Mandrel diameter and tension shall be as given in Table 10. Test temperature 150 2 C. Time 100 h Mandrel diameter and tension shall be as given in Table 10 Mandrel diameter and tension shall be as given in Table 10. Test temp
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