EN 2591-503:2001

Overview

EN 2591-503:2001 is a European standard developed by CEN (European Committee for Standardization) that focuses on aerospace electrical and optical connectors. Specifically, it addresses the test methods for assessing contact deformation after crimping. Crimping is a critical process in the assembly of electrical and optical connections, ensuring reliable mechanical and electrical performance. This standard complements EN 2591-100 and mandates how deformation should be evaluated to maintain connector integrity in aerospace applications.

Key Topics

• Scope of Standard: Specifies a method to assess deformation in contacts post-crimping, ensuring components meet rigorous aerospace requirements.
• Specimen Preparation: Samples must be crimped with cables at both maximum and minimum cross-sectional areas permitted for each contact size.
• Measurement Method: Uses a rotating test device to measure the excentricity and deformation around 360° without causing any additional deformation.
• Acceptance Criteria:
  • Contact excentricity must not exceed predetermined values after rotation.
  • The crimp barrel opening must be within defined limits.
  • No cracks are allowed at three times magnification, ensuring mechanical reliability.
• Apparatus Requirements: Test device must allow free rotation with minimal added eccentricity (<1%) and avoid deformation from holding methods.
• Referenced Standards: To be used in conjunction with EN 2591-100 (general test methods) and EN 2591-102 (dimension and mass examination).

Applications

EN 2591-503:2001 applies to manufacturers, quality engineers, and test laboratories involved in the aerospace sector. It is essential for:

• Aerospace Connector Manufacturing: Ensures crimped contacts in electrical and optical connectors meet exact deformation tolerances, preventing connection failures.
• Quality Control: Confirms crimping process consistency and connector integrity during production.
• Design Verification: Supports design validation of connector elements by providing standardized deformation assessment.
• Reliability Testing: Detects potential structural weaknesses early to improve long-term performance in harsh aerospace environments.
• Supplier Compliance: Enables aerospace OEMs and contractors to verify that suppliers comply with stringent contact crimping standards.

Related Standards

• EN 2591-100: General test methods for electrical and optical connection elements in aerospace.
• EN 2591-102: Procedures for dimensional and mass inspection critical to the accurate preparation of test specimens.
• Other aerospace and electrical connection standards that govern materials, assembly, and testing procedures within European and international regulatory frameworks.

Benefits of Compliance

• Enhanced Safety: Minimizes risk of electrical failures due to poor crimping or contact deformation.
• Improved Reliability: Helps maintain optimum mechanical and electrical performance under aerospace operational conditions.
• Consistency: Standardized test procedures facilitate uniform assessment across manufacturers and international supply chains.
• Regulatory Alignment: Meets mandatory European aerospace industry standards, aiding in certification processes.

By adopting EN 2591-503:2001, aerospace industry stakeholders ensure that crimped contacts in electrical and optical connectors uphold the highest standards of quality and reliability, essential for mission-critical aerospace applications.