Lab 6 AERM 1345-1

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Tarrant County College, Fort Worth *

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1314

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Mechanical Engineering

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Dec 6, 2023

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Laboratory/Learning Outcomes AERM 1345 Lab Project 6 Repair and inspect aircraft electrical system components; crimp and splice wiring to manufactures specifications. a. Student will select the proper solderless (crimp and slice) termination, tools and then properly terminate a wire b. Student will properly terminate and inspect a wire using solder c. Inspect solderless (crimp and splice) terminations and list defects d. Student will repair a broken/damaged wire by selecting the correct tools and solderless (crimp and splice) termination e. Student will Use acceptable data select material, fabricate, install, and test a circuit ground ACS Element - S - Skills The student demonstrates the ability to: AM.II.K.S2 Perform wire terminating and splicing. AM.II.K.S18 Perform a continuity test to verify the condition of a conductor. AM.II.K.S19 Perform a test on a conductor for a short to ground. AM.II.K.S20 Perform a test on a conductor for a short to other conductors. Answer the Following Questions: 1. What is an electrical connector? Answer: It’s a device that is used to terminate or connect the conductors of individual wires/cables to other wires/cables or components 2. What are the two parts to every connector assembly? Answer: Plugs and Receptacles 3. Plugs typically use what type of contact? Answer: Pin Contact and socket contacts 4. Receptacles typically use what type of contact? Answer: A device for mating connectors by engaging threads in a coupling ring with threads on a receptacle shell. 2.5.1 Course Outline: AERM 1345 September 21, 2022 Page 1 of 7
5. Define a “high reliability connector”. Answer: Something that you can trust more than the other connector uses. 6. What are the two forms of connectors? Answer: Soldered and Solderless 7. What are the benefits of using connectors in aircraft wiring? Answer: Connectors facilitate maintenance when frequent disconnection is required. 8. What five parts make up a connector? Answer: Housing, Insulator, Contacts, Strain Relief, Coupling Mechanism 9. What part of the connector assembly (receptacle or plug) is used as the ground side of the circuit? Answer: Pin contact (Receptacle) 10.Of the connector, (receptacle or plug) which is the power side of the circuit? Answer: Plug 11.Which contact carries power (+)? Answer: Sockets 12.Which contact is ground (-)? Answer: Pin Contact 13.How many rows of contacts does a low density rectangular connector have? Answer: They are 1 14.How many rows of contacts does a standard density rectangular connector have? Answer: 2 15.How many rows of contacts does a high density rectangular connector have? Answer: 3 2.5.1 Course Outline: AERM 1345 September 21, 2022 Page 2 of 7
16.What are the three different connector coupling mechanisms that are used to mate receptacles and plugs? Answer: 1: Circular connector with bayonet coupling. 2: Circular connector with threaded coupling. Front release contacts. 3: Circular connector, threaded coupling. 17.What are the two primary requirements of a properly formed contact/conductor crimp? Answer: Mechanical Strength and Electrical Grip 18.What is the strength requirement of a properly crimped contact? Answer: 100% tensile strength of wire 19.What is the purpose of the inspection hole on a connector contact? Answer: Ensure the cable is properly in the contact 20.Using Daniel Manufactures website, determining the following information for the following contact color bands? Contact Type Standard Density Socket Bin Orange Blue Grey Crimper AFA _ CRIMP TOOL M22520/1-01 Positioner ___ 86-30-1 positioner _____________ Insertion Tool ___ DAK145 Insertion Too l___________ Removal Tool ___ DRK 145___Removal Tool #20 ______ 21.Properly number all of the contacts on the connector below. Answer: 1)__ 6 ___ 2)__ 7 ___3)___ 8 __4)__ 5 ___5)__ 1 ___6)__ 9 ___7)__ 16 ___8)__ 4 ___9)__ 2 ___ 10)__ 10 ___11)__ 15 ___12)__ 3 ___13)__ 11 ___14)__ 14 ___15)_ 13 ___ 16)__ 12 ___ 2.5.1 Course Outline: AERM 1345 September 21, 2022 Page 3 of 7
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Lab Performance Prepare the wiring harness to attach connectors. Refer to the Daniels DMC tool catalogs on Canvas, . 1. Please acquire connectors and put a tape label with your name on it on the plastic container. Make the wires approximately 18 in. long from 20 AWG wire from the tool room. 2. The connectors will be identified as SUB-D 1, SUB-D 2, RP-3 and RP-4. 3. SUB-D 1 and SUB-D 2 are M24308/2. Refer to DMC Tools PDF Catalogs provided on Canvas, Connector Tooling Guide in the LRC and find the data sheet and tooling requirements for these connectors. Attach to this lab. 4. Provide the following information terminate wires using wiring diagram below 5. Test harness using tester box. 6. Grading will be based on proper hardware, crimped connections, splicing and correct wire numbering. 7. Round connectors, o ne should be a male, P/N MS3126F10-6P, the other should be female, P/N MS3126F-6S. Ensure that the male connector has a red band painted on its collar, and the female connector has a blue band painted on its collar. 8. Install wires 008-20 to C on CP-4, 007-20 to B on CP-3, 009-20 to E on CP-4 and 006-20 to F on CP-3. After installation, and test, demonstrate your ability to remove the contacts from the connector. After instructor grades your project, de- pin the crimp connectors and cut the wires connecting SUB-D 1 to SUB-D 2 and return to the tool room. 9. Test wiring harness using tester box. 2.5.1 Course Outline: AERM 1345 September 21, 2022 Page 4 of 7
2.5.1 Course Outline: AERM 1345 September 21, 2022 Page 5 of 7
Connector Type ____Round___________________________ Connector Density __ Standard Density _____________________ Connector Part Number __ MS3126F10-6S/ MS3126F10-5P _________ Contact BIN __ Orange, Blue and Black ________________ Contact Size __ 22 ___________________________________ Contact Removal (Front/Rear) DRK95-22MB Removal Tweezer - M81969/8-02 REV B Required Tooling o Crimper AFM8 Adjustable Miniature 8 Indent Lower Range Crimp Tool , MIL-DTL- 22520/2* and AS22520/2* o Contact Positioner K42 Positioner MIL-DTL-22520/2* and AS22520/2* o Insertion Tool DAK95-22MB Insertion Tweezer - M81969/8-01 REV B o Contact Removal Tool DRK95-22MB Removal Tweezer - M81969/8-02 REV B 2.5.1 Course Outline: AERM 1345 September 21, 2022 Page 6 of 7
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Remove all contacts from connectors. Reassemble connectors for return to tool room. 2.5.1 Course Outline: AERM 1345 September 21, 2022 Page 7 of 7