Tooling Guide for Aerospace Wiring Systems

1 Tooling Guide for Aerospace Wiring Systems An & ISO. A. Re S91 900. Co gis 00 1:2. m te :20 00. pa re 0 8. ny d 4. Preface and Table of Contents Daniels tools have been utilized in military aircraft The people behind the DMC name are pleased and Aerospace programs for over 60 years (DMC to present our Connector Assembly Tools and founded in 1949). By continuously planning and Accessories on the pages that follow. We believe the adding to our product lines, we are now fulfilling the application data which accompanies each section demands of other high technology fields such as will answer your specific questions concerning telecommunications, fiber optics, lasers, and many Tooling ; however, we encourage you to contact us other areas of electronic packaging.

2 By telephone or fax for the personal services of our knowledgeable staff of application experts. Battery Powered Hydraulic CONTENTS Open Frame Crimp Important Facts About Pneumatic Open Frame Tensile Test X-Die Pneumatic Tool/Bench Press Hand MPT-250B (Motorized 250 lb)..3 Electric Hydraulic Open Frame Crimp PT-150H (Manual 150 lb)..4. HPT-200 (Portable, Manual 200 lb)..5 DMC Y-Dies For A Full Range of Standard Adjustable Indent Crimp Typical Y-Die Configurations and Applications M22520/1-01 (AF8) Coaxial Contact Tool Selection Miniature Adjustable Indent Crimp Connectors Tool Selection M22520/2-01 (AFM8)..8 Mid-Current Range Adjustable M22520/7-01 (MH860)..9 Indent Crimp M22520/34-01 (39-000).

3 9 Circular Indent Crimp Battery Powered Hydraulic Indent Crimp Special Application Indent Crimp Pneumatic Indent Crimp MH835 & MH992 (Fine Tipped Indenter Tools)..98. Auto-Lift Pneumatic MH800 (Ultra Precision)..99. Indent Crimp MH820 (Stainless Steel Indentor)..99. SC8 & MH993 (Biased Crimp Tools)..100. Large Gage Pneumatic Indent Crimp Dedicated Application Indent Crimp M22520/23-01 (WA23). LH8 (for Burndy YHMM Series Contacts). Large Gage Contact Application GS217 (MIL-C-22442/32-1 Clamping Ring Crimp Tool). Technical Application Guide for GMT Series Precision Crimp Contacts and Battery Powered Hydraulic GMT Crimp Connector Contact Color Code (BIN)..22 DCT Series Crimp M39029 Contact Quick Location Hydrac Ton Hydraulic Y-Die Crimp MIL-STD-1760 Connector Hydrac Ton Hydraulic HD36-Die Crimp Installing and Removal Hydrac Ton Hydraulic HD51-Die Crimp MIL-I-81969.

4 Hydrac 7 & 12 Ton Hydraulic Crimp Tool Contact Retention Test for HD002, HD485, and HD442 Dies (AS5259)..114. Contact Air Powered Hydraulic Pump (HPU11M)..116. Unwired Contact Removal Hydrac 7 Ton Dieless Four Indent M81969/30 Wire Harness BETA Backshell Torque Cable Tie Removal EMI/RFI Band Application Technical Application Guide for MIL Spec Circular Indent Crimp Terminals and M22520/4-01 (GS100-1) Hand-Held Pneumatic Wire Stripping M22520/31-01 (GS200-1) Swaging Tool & Tool Open Frame Crimp Wiring System Service M22520/5-01 (HX4) Limited M22520/10-01 (HX3). DANIELS MANUFACTURING CORP. 526 THORPE RD. ORLANDO, FL 32824 NOTICE. PHONE 407/855-6161 FAX 407-855-6884 ANY PRICES WE QUOTE VERBALLY OR ANY PRICES APPEARING IN.

5 E-MAIL: OUR PRINTED PRICE LISTS ARE SUBJECT TO CHANGE WITHOUT. CAGE CODE: 11851 PRIOR NOTICE. IF YOU NEED FIRM PRICES FOR FUTURE DELIVERIES. YOU SHOULD REQUEST A WRITTEN QUOTATION FROM OUR SALES. OFFICE. WE ARE NOT LIABLE FOR CONSEQUENTIAL OR SPECIAL. FOR WARRANTY & LIMITATION OF LIABILITY DAMAGES OF ANY NATURE OR KIND, RESULTING FROM THE USE OF. ANY OF OUR PRODUCTS. INFORMATION SEE PAGE 172. Copyright 2012 Daniels Manufacturing Corp. ALL RIGHTS RESERVED Important Facts About Crimping Time Line for Crimp MS3191-4 also introduced the use of Specifications state the requirements Technology the double tipped indenter to produce in terms of millivolt drop at a designated 1940s All terminations were soldered an eight indent crimp pattern which has current.

6 (Hard-wired) consistently achieved superior tensile pull The mechanical strength of a crimped 1953 AMP introduced Crimp off values. joint and hence its pull-out force (tensile Barrel Terminals MS3191-4 introduced the concept of strength), varies with the deformation 1957 Cannon Brothers experimented a turret head containing three locators applied. Therefore, by properly shaping with Machined Contacts with which could be used without separating the deformation a high pull-out force can Crimp Barrels any of them from the basic crimp tool. be achieved, the crimp die of the tool 1960 Buchanan introduced the In 1969 two military specifications for determines the crimp configuration and 4 Indent Crimp Tool with a crimp tools were developed to replace deformation.

7 Ratchet (Ref: MS3191) the existing military drawings. They were The dies in the tool determine the 1963 MS3191-1 was published as the MIL-T-22520C (Navy) and MIL-T-83724 completed crimp configuration which first Crimp Tool Standard. (USAF) which defined a standard size is generally an element of contact and/. 1965 MS3191-4 introduced by crimp tool similar to the MS3191-4, but or connector design. Some of the design Daniels Manufacturing Corp. with an expanded eight step crimp depth considerations are: a) The type of contact, 1969 MIL-T-22520 published range. These specifications also defined a its size, shape, material and function, and dated to replace all miniature crimp tool to crimp conductors b) The type and size of wires to be previous specifications as small as AWG 32.

8 Accommodated, c) The type of Tooling 1974 Changed to MIL-C-22520, Both documents were combined in into which the configuration must be built. and many Slash Sheets added 1971 into MIL-C-22520D. All previous 1996 Changed to MIL-DTL-22520 military standards for crimp tools were 2010 Changed to AS22520 then cancelled including the MS3191. This list includes specifications for indent crimp tools, terminal lug crimp tools, CRIMPING: THEN AND NOW pneumatic tools, coaxial cable crimp tools The first multi-pin connectors were and connector service kits. terminated by soldering the conductor to MIL-DTL-22520 established a single Eight Indent non-removable contacts. However, high specification which set forth performance temperature applications and the need for requirements for all crimp tools to be used simple and reliable field service led to the on military standard electrical connectors.

9 Introduction of connectors with removable This eliminated the waste and confusion Four Indent contacts. These were crimped onto the which accompanied the overlapping appli- conductor rather than being soldered. cations of many different standard crimp The first standard crimp tool developed tools called out by a deluge of unrelated to crimp these new contacts was intro- military drawings. Two Indent duced in the early sixties. MS3191-1, a military drawing, defined this tool and its accessories. The MS3191-1 utilized THE CRIMPING CONCEPT. a four indent crimp pattern together with Crimping is a method of firmly Hexagonal Crimp a positive stop locator which controlled attaching a terminal or contact end to an the travel of the indenters (crimp depth).

10 Electrical conductor by pressure forming The MS3191-1 design was a compro- or reshaping a metal barrel together mise between simplicity of operation and with the conductor. The forming of a Circular Crimp crimp performance since the crimp depth satisfactory crimp depends on the correct for any given contact was not adjustable combination of conductor, crimp barrel to accommodate the differing diameters and tool. of the conductors to which it would be When applied with a properly matched B Crimp crimped. It was, however, suitable for the tool, a union is established which has crimp connectors of that era. both good electrical and mechanical An improved tool design featuring characteristics.