This ESA-authorized training provides basic information on the use of materials in the space environment and is designed to teach practical skills and theory related to Crimping and Wire Wrapping Processes. The training is based on the ECSS-Q-ST-70-26 standard “High Reliability Crimped Electrical Connections” and ECSS-Q-ST-70-30 “High Reliability Wire Wrapped Connections”.
This training is intended for Production Operators, Quality Assurance Engineers, and those in Design and Production. The training provides hands-on experience. All necessary tools and equipment are provided, although participants may bring their own hand tools if they wish.
Training Objectives
- Learn and understand the requirements of both ECSS standards.
- Identify factors that affect the quality, reliability, and performance of crimped and wrapped wire connections.
- Develop correct assembly and testing methods.
- Develop skills in identifying and analyzing errors related to termination methods.
Experience and Prerequisites
- Knowledge of electronic wiring and assembly processes.
- Good practical skills.
- Positive attitude towards high-quality workmanship.
- Visual acuity certificate in accordance with ESA STR 258 document.
Training Plan
Day 1
- Complete the student registration form
- Provide visual acuity test certificate
- Introduction and orientation, including safety, equipment, procedures, and break times
- Training presentation: what we will learn, how, why, and when
- Overview of specification structure: relevant ECSS standards; release status and how to access them
- Theory of non-soldered connection methods
- Knowledge of key parameters affecting connection quality and performance
- Advantages and disadvantages of these process techniques compared to soldering
- Presentation of ECSS-Q-ST-70-26; multiple-choice operator test (all students must achieve a minimum of 80% on 25 questions, open-book test)
- Tools and indicators
- Crimping templates
- Selection and preparation of wires and terminations
- Connecting samples for tensile testing
Day 2
- Dispersive crimping
- Use of spreadsheet; variance and process capability
- Analysis of results
- Compact crimping
- Analysis of results
- Presentation of ECSS-Q-ST-70-30; multiple-choice operator test (all students must achieve a minimum of 80% on 25 questions, open-book test)
- Wire-wrap tools
- Wire wrapping posts and wire selection
- Wire wrapping
- Recording and analyzing results
Day 3
- Self-inspection of work
- Cleaning and inspection tools
- Certification
Certificate
According to this document, upon successful completion of the training, a Category 2 Certificate approved by ESA will be awarded. Candidates already holding a valid Category 2 Inspector certificate will be eligible to receive a Category 2 certificate for this subject. Authorization is valid for two years (see note on 9-month extension under RECERTIFICATION below).
Duration, Schedule, and Fees
2½ days (plus ½ day if retake exams are required).
Recertification
To renew the certificate for another two years, attendance at a one-day recertification training is required. The two-year period can be extended by up to 9 months if previous recertification sessions cannot be attended.