EN 2242-2012 pdf download.Aerospace series – Crimping of electric cables with conductors defined by EN 2083, EN 4434 and EN 2346.
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
crimping mechanism
mechanism controlling the total crimping cycle; fitted with a device which prevents the tool from returning to open position before the completion of this cyde
3.2
test piece
consists of a length of terminated cable
(For further definitions, see IEC 60050-581J
4 General requirements for crimping
The cable cross-section shall be compatible with the crimp barrel and be within the limits defined in the specification for connectors, connection components and tooling being used. It shall be verified that the combination conductor – crimp tool – crimp barrel” complies with the requirements of the wiring and has been qualified by the responsible authorities.
The crimping of the conductor shall be carried out in a single operation with the aid of the appropriate tooling approved by the manufacturer of the connection components. This operation shall not require any additional heating or cooling.
No additional operation such as brazing, etc. shall be carried out on a crimped connection.
The organization and preparation of the work area shall be such that:
— the tooling is constantly maintained in good condition;
— a check can be made that only the tools and accessories adapted to this type of crimping are usea;
– there have been no adjustments to the tooling.
During handling and transport, the crimped connections shall not be subjected to any stress likely to cause deterioration.
5 Tooling
The crimping tools and their accessories shall be approved by the responsible authorities.
6.1 General
Before manufacturing, test pieces shall be prepared for each combination “conductor – cnmp tool – crimp barrel
to be tested to qualify the crimping process.
6.2 Checking of tooling
6.2.1 Stripping tool
Before stripping, ensure that the stripping tool has been inspected and meets the requirements of EN 2812.
6.2.2 Crimping tool
Ensure that the crimping tool has been inspected and that the crimping mechanism is functioning correctly.
6.3 Preparation of test pieces
The test pieces shall be tracable to the electrical cable they represent.
6.4 Inspection prior to crimping
Check that the connection components and the cable conform to the definition documentation.
In addition to the general requirements (see Clause 4), the connection components shall be clean, free from any trace of corrosion and shall not show any defects. However, a uniform and superficial discoloration is tolerated.
The cable shall be stripped in accordance with EN 2812.
Crimping of multiple conductors
In the case of crimping two conductors in one connection component, the following conditions shall be observed:
— the sum of the two actual sections of the conductors shall be compatible with the section permitted by the connection component;
— the stripping lengths of the cable ends shall be identical;
— all the strands of the two conductors, placed parallel to each other, shall enter easily into the connection corn ponent;
— the crimping operation shall not cause any offset of one conductor in relation to the other;
6.6.1 General
They shall be carried out on five test pieces of the minimum conductor cross-section and five test pieces of the maximum conductor cross-section.
These tests shall be repeated if one of the following conditions changes:
material of strands of the conductors;
— metallic covering of strands: tin plating, silver or nickel plating, etc.;
— size of connection components;
types of tools used, with corresponding accessories.
6.6.2 Visual inspection
It shall be carried out on all test pieces [see Annex A (normative) and Annex B (normative)J:
Ensure that:
— the form and location of the crimps are correct, see Figure A. 1, Figure A.2 and Figure A.3;
the stripping length is correct and that the strands of the conductor are all correctly inserted in the barrel (conductor visible through the inspection hole), see Figure A.3;
— the distance between the insulation of the cable and the barrel is such that no bending of the cable can exert stress in the area of the barrel, see Figure A.2;
— the conductor at the rear of the barrel is not deformed, see Figure A.2;
— the connection component shows no defects and no burr, sharp edge, crack or lift off of the protection, or distortions according to EN 2591-503.
Requirement: if the inspection is not satisfactory, the crimping process shall be revised.
6.6.3 Tensile test
Each test piece which has satisfied the visual inspection shall be submitted to the tensile strength test according to EN 2591-417. Insulation grip shall be rendered ineffective, before the test is carried out.
Requirement: if one of the crimped connections fractures at a value lower than that specified in Table 1, the crimping process shall be reviewed.EN 2242-2012 pdf download.

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