The aerospace industry is a high – precision and high – risk field, where the reliability and safety of every component are crucial. Industrial cables, as the “nervous system” that transmits power and signals in aerospace equipment, must comply with strict and comprehensive standards to ensure the stable operation of the entire aerospace system. These standards cover multiple aspects such as electrical performance, mechanical properties, environmental adaptability, and flame retardancy, forming a rigorous quality control system.
Electrical performance is the core indicator of industrial cables in the aerospace industry, directly related to the accuracy of power transmission and signal transmission. First of all, the insulation resistance of the cable must meet high requirements. According to the international standard IEC 60092 – 350, the insulation resistance of aerospace cables at 20°C should not be less than 100 MΩ·km. This ensures that there is no leakage current between the cable conductor and the outer insulation layer, avoiding power loss and potential safety hazards.
Secondly, the voltage withstand performance is also a key standard. Aerospace cables need to undergo a voltage withstand test under specified conditions. For example, in accordance with SAE AS 22759, the cable should withstand an AC voltage of 1500 V for 1 minute without breakdown. This test simulates the high – voltage environment that the cable may encounter during operation, ensuring that it can maintain normal insulation performance under extreme electrical conditions.
In addition, the electromagnetic compatibility (EMC) of the cable is essential. The aerospace environment is filled with complex electromagnetic signals, and the cable must have good shielding performance to prevent external electromagnetic interference from affecting the internal signal transmission and avoid the electromagnetic radiation of the cable itself interfering with other equipment. The standard MIL – STD – 461 specifies the EMC requirements for aerospace components, including cables. Generally, the shielding effectiveness of aerospace cables should be not less than 85 dB in the frequency range of 100 MHz – 1 GHz.
Aerospace equipment will experience various mechanical stresses during manufacturing, installation, and operation, such as tension, bending, torsion, and vibration. Therefore, industrial cables must have excellent mechanical properties to resist these stresses.
The tensile strength of the cable conductor is clearly regulated. According to ISO 6266, the tensile strength of copper conductors used in aerospace cables should be at least 200 MPa, and the elongation at break should not be less than 15%. This ensures that the conductor will not break or deform under the action of tension during installation and use.
Bending performance is another important mechanical indicator. The standard EN 3475 – 701 stipulates that aerospace cables should be able to withstand repeated bending without damage. For example, a cable with a diameter of 5 mm should be able to complete 10,000 bending cycles at a bending radius of 25 mm (5 times the cable diameter) without breaking the conductor or cracking the insulation layer.
Vibration resistance is also crucial. During the flight of an aircraft or the operation of a spacecraft, the cable will be in a continuous vibration environment. The standard RTCA DO – 160 specifies the vibration test conditions for aerospace cables, including different vibration frequencies and amplitudes. The cable must maintain normal electrical performance and structural integrity after undergoing the specified vibration test.
The aerospace environment is extremely harsh, involving extreme temperatures, humidity, radiation, and chemical corrosion. Industrial cables must have strong environmental adaptability to ensure stable performance in these harsh conditions.
High – and low – temperature resistance is a basic requirement. Aerospace cables should be able to work normally in a wide temperature range. According to MIL – DTL – 24643, the operating temperature range of most aerospace cables is – 65°C to 200°C. Some special cables used in engine compartments or near heat sources even need to withstand temperatures above 300°C. The cable insulation and sheath materials must maintain good flexibility and insulation performance within this temperature range, without hardening, cracking, or melting.
Humidity resistance is also an important standard. In some aerospace scenarios, such as aircraft flying in humid air or spacecraft in the earth’s atmosphere, the cable will be exposed to high – humidity environments. The standard IEC 60092 – 354 requires that after the cable is subjected to a humidity test (relative humidity of 95% ± 3%, temperature of 40°C ± 2°C) for 28 days, its insulation resistance should not be less than 10 MΩ·km, and there should be no signs of corrosion on the conductor.
Radiation resistance is necessary for cables used in spacecraft. Space is filled with various types of radiation, such as cosmic rays and solar flares, which will cause damage to the cable materials and affect the cable’s performance. The standard ISO 10254 specifies the radiation resistance requirements for aerospace cables. The cable should be able to withstand a total radiation dose of at least 100 kGy without significant degradation in electrical and mechanical properties.
In the closed environment of aerospace equipment, such as aircraft cabins and spacecraft compartments, if a cable catches fire, it will not only cause direct damage but also produce a large amount of smoke and toxic gases, endangering the safety of personnel and equipment. Therefore, aerospace cables must meet strict flame retardancy and smoke toxicity standards.
The flame retardancy of the cable is tested in accordance with the standard UL 94. Aerospace cables are generally required to reach the V – 0 level, which means that when the cable is ignited with a flame, the flame should be extinguished within 10 seconds after the flame is removed, and there should be no dripping of burning materials that can ignite the cotton below.
In terms of smoke toxicity, the standard BS 6853 specifies the smoke density and toxic gas emission requirements for materials used in railway and aerospace vehicles. For aerospace cables, the specific optical density (SOD) of smoke generated during combustion should not exceed 200 within 4 minutes, and the concentration of toxic gases such as carbon monoxide and hydrogen chloride should be lower than the specified safety limits.
In conclusion, the standards for industrial cables in the aerospace industry are comprehensive and strict, covering multiple aspects to ensure the reliability, safety, and stability of the cables in the harsh aerospace environment. Compliance with these standards is not only a requirement for the production of aerospace cables but also a guarantee for the safe operation of aerospace equipment.
When it comes to high – quality aerospace industrial cables that meet all these strict standards, FRS brand factory is a trustworthy choice. FRS has long been committed to the R & D and production of aerospace – grade industrial cables. Every cable produced by FRS undergoes rigorous testing in accordance with international aerospace standards, from the selection of high – quality conductors and insulation materials to the strict control of the production process. Whether it is electrical performance, mechanical properties, or environmental adaptability, FRS cables can meet or even exceed the industry’s strict requirements. Choosing FRS means choosing reliability and safety for your aerospace projects.
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