Aircraft Control Cable

Aircraft Control Cable
Aircraft Control Cable
# CABLES ARE THE MOST WIDELY USED LINKAGE IN PRIMARY FLIGHT CONTROL
SYSTEMS.
# CABLE-TYPE LINKAGE IS ALSO USED IN ENGINE CONTROLS, EMERGENCY EXTENSION
SYSTEM FOR THE LANDING GEAR, AND VARIOUS OTHER SYSTEMS THROUGHOUT THE
AIRCRAFT.
# CABLE-TYPE LINKAGE HAS SEVERAL ADVANTAGES OVER THE OTHER TYPES.
1) IT IS STRONG AND LIGHT IN WEIGHT,
2) ITS FLEXIBILITY MAKES IT EASY TO ROUTE THROUGH THE AIRCRAFT.
3) AN AIRCRAFT CABLE HAS A HIGH MECHANICAL EFFICIENCY AND CAN BE
SET UP WITHOUT BACKLASH, WHICH IS VERY IMPORTANT FOR PRECISE CONTROL.
# CABLE LINKAGE ALSO HAS SOME DISADVANTAGES.
1)TENSION MUST BE ADJUSTED FREQUENTLY DUE TO STRETCHING AND
TEMPERATURE CHANGES.
Cable Construction:
# AIRCRAFT CONTROL CABLES ARE FABRICATED FROM GALVANIZED CARBON
STEEL OR CORROSION RESISTANT STEEL.
# THE BASIC COMPONENT OF A CABLE IS A WIRE. THE DIAMETER OF THE WIRE
DETERMINES THE TOTAL DIAMETER OF THE CABLE.
# A NUMBER OF WIRES ARE PREFORMED INTO A HELICAL OR SPIRAL SHAPE
AND THEN FORMED INTO A STRAND.
# THESE PREFORMED STRANDS ARE LAID AROUND A STRAIGHT CENTER
STRAND TO FORM A CABLE.
# CABLE DESIGNATIONS ARE BASED ON THE NUMBER OF STRANDS AND THE
NUMBER OF WIRES IN EACH STRAND. THE MOST COMMON AIRCRAFT CABLES
ARE THE 7 X 7 AND 7 X 19.
# THE 7 X 7 CABLE CONSISTS OF SEVEN STRANDS OF SEVEN WIRES EACH. SIX OF
THESE STRANDS ARE LAID AROUND THE CENTER STRAND.
# (This is a cable of medium flexibility and is used for trim tab controls, engine
controls, and indicator controls.)
7 X 19 cable:
# THE 7 X 19 CABLE IS MADE UP OF SEVEN STRANDS OF 19 WIRES EACH.
# SIX OF THESE STRANDS ARE LAID AROUND THE CENTER STRAND.
# AIRCRAFT CONTROL CABLES VARY IN DIAMETER, RANGING FROM 1/16 TO 3/8.
THE DIAMETER IS MEASURED AS SHOWN.
This -cable is extra flexible and is used in primary control systems and in other places
where operation over pulleys is frequent.
Different constructions of aircraft cable?
7 x 19 7x7 3x7 1 x 19 1x7

Cable Fittings:
# CABLES MAY BE EQUIPPED WITH SEVERAL DIFFERENT TYPES OF FITTINGS SUCH AS
TERMINALS, THIMBLES, BUSHINGS, AND SHACKLES.
# TERMINAL FITTINGS ARE GENERALLY OF THE SWAGED TYPE.
# THEY ARE AVAILABLE IN THE THREADED END, FORK END, EYE END, SINGLE-SHANK
BALL END, AND DOUBLE-SHANK BALL END.
# THE THREADED END, FORK END, AND EYE END TERMINALS ARE USED TO CONNECT
THE CABLE TO A TURNBUCKLE, BELL CRANK, OR OTHER LINKAGE IN THE SYSTEM.
# THE BALL-END TERMINALS ARE USED FOR ATTACHING CABLES TO QUADRANTS
AND SPECIAL CONNECTIONS WHERE SPACE IS LIMITED.
# THE THIMBLE, BUSHING, AND SHACKLE FITTINGS MAY BE USED IN PLACE OF SOME
TYPES OF TERMINAL FITTINGS WHEN FACILITIES AND SUPPLIES ARE LIMITED AND
IMMEDIATE REPLACEMENT OF THE CABLE IS NECESSARY.
Cable Fittings:
THE THIMBLE, BUSHING, AND SHACKLE FITTINGS MAY BE USED IN PLACE OF SOME TYPES OF
TERMINAL FITTINGS WHEN FACILITIES AND SUPPLIES ARE LIMITED AND IMMEDIATE
REPLACEMENT OF THE CABLE IS NECESSARY.
INSPECTION ON CONTROL CABLE:
AT EACH REGULAR INSPECTION PERIOD, CABLES SHOULD BE INSPECTED FOR BROKEN WIRES
BY PASSING A CLOTH ALONG THEIR LENGTH AND OBSERVING POINTS WHERE THE CLOTH
SNAGS.
TO THOROUGHLY INSPECT THE CABLE, MOVE THE SURFACE CONTROL TO THEIR EXTREME
TRAVEL LIMITS.
THIS WILL REVEAL THE CABLE IN PULLEY, FAIRLEAD, AND DRUM AREAS. IF THE SURFACE OF
THE CABLE IS CORRODED, RELIEVE CABLE TENSION. THEN CAREFULLY FORCE THE CABLE OPEN
BY REVERSE TWISTING, AND VISUALLY INSPECT THE INTERIOR FOR CORROSION. CORROSION
ON THE INTERIOR STRANDS OF THE CABLE INDICATES FAILURE OF THE CABLE AND REQUIRES
REPLACEMENT OF THE CABLE. IF THERE IS NO INTERNAL CORROSION, REMOVE EXTERNAL
CORROSION WITH A COARSE WEAVE RAG OR FIBER BRUSH. NEVER USE METALLIC WOOLS OR
SOLVENTS TO CLEAN FLEXIBLE CABLE. METALLIC WOOLS IMBED DISSIMILAR METAL PARTICLES,
WHICH CAUSE FURTHER CORROSION. SOLVENTS REMOVE THE INTERNAL CABLE LUBRICANT,
WHICH ALSO RESULTS IN FURTHER CORROSION.
AFTER THOROUGHLY CLEANING THE FLEXIBLE CABLE, APPLY CORROSION-PREVENTIVE
COMPOUND. THIS COMPOUND PRESERVES AND LUBRICATES THE CABLE.
BREAKAGE OF WIRES OCCURS MOST FREQUENTLY WHERE CABLES PASS OVER PULLEYS AND
THROUGH FAIRLEADS. TYPICAL BREAKAGE POINTS ARE SHOWN IN FIGURE 2-57. CONTROL
CABLES AND WIRES SHOULD BE REPLACED IF WORN, DISTORTED, CORRODED, OR OTHERWISE
DAMAGED.
Lockclad cable:
# LOCKCLAD CABLE IS USED ON SOME LARGE AIRCRAFT FOR ALL LONG, STRAIGHT
RUNS.
# IT CONSISTS OF THE CONVENTIONAL FLEXIBLE STEEL CABLE WITH ALUMINUM
TUBING SWAGED TO IT TO LOCK THE CABLE INSIDE THE TUBING.
# LOCKCLAD CABLE CONSTRUCTION HAS CERTAIN ADVANTAGES :
A) CHANGES IN TENSION DUE TO TEMPERATURE ARE LESS THAN
WITH CONVENTIONAL CABLE.
B) THE AMOUNT OF STRETCH AT A GIVEN LOAD IS LESS THAN WITH
CONVENTIONAL CABLE.
# LOCKCLAD CABLES SHOULD BE REPLACED WHEN THE COVERING IS WORN
THROUGH, EXPOSING WORN WIRE STRANDS IS BROKEN; OR SHOWS WORN SPOTS
WHICH CAUSE THE CABLE TO BUMP WHEN PASSING OVER FAIRLEAD ROLLERS.
Control system components
MANY COMPONENTS ARE INVOLVED IN THE OPERATION OF
CONTROL SYSTEM, SOME OF THEM ARE DISCUSSED BELOW:
TURN BUCKLE: # A TURNBUCKLE ASSEMBLY IS A MECHANICAL SCREW DEVICE

CONSISTING OF TWO THREADED TERMINALS AND A THREADED BARREL. FIGURE
ILLUSTRATES A TYPICAL TURNBUCKLE ASSEMBLY.
# Turnbuckles are fitted in the cable assembly for the purpose of making minor
adjustments in cable length and for adjusting cable tension.
One of the terminals has right-hand threads and the other has left-hand threads.
Turn buckle:
THE END OF THE BARREL WITH THE LEFT-HAND THREADS CAN USUALLY BE
IDENTIFIED BY A GROOVE OR KNURL AROUND THAT END OF THE BARREL.
WHEN INSTALLING A TURNBUCKLE IN A CONTROL SYSTEM, IT IS NECESSARY TO

SCREW BOTH OF THE TERMINALS AN EQUAL NUMBER OF TURNS INTO THE BARREL.
IT IS ALSO ESSENTIAL THAT ALL TURNBUCKLE TERMINALS BE SCREWED INTO THE

BARREL UNTIL NOT MORE THAN THREE THREADS ARE EXPOSED ON EITHER SIDE OF
THE TURNBUCKLE BARREL.
AFTER A TURNBUCKLE IS PROPERLY ADJUSTED, IT MUST BE SAFETIED.
Safetying of Turnbuckles
Clip-locking method;
Safetying of Turnbuckles
Wire-wrapping method.
Pulleys :
Pulleys are used to guide cables and also to change the direction of cable
movement.
Pulley bearings are sealed, and need no lubrication other than the lubrication
done at the factory.
 Brackets fastened to the structure of the aircraft support the pulleys.
Cables passing over pulleys are kept in place by guards. The guards are close-
fitting to prevent jamming or to prevent the cables from slipping off when they
slacken due to temperature variations.
Bell crank:
A bell crank is used to transmit force and permit a change in the

direction of force.
A fairlead may be made from a nonmetallic material, such as phenolic or a
metallic material such as soft aluminum.
The fairlead completely encircles the cable where it passes through holes in bulkheads
or other metal parts. Fairleads are used to guide cables in a straight line through or between st
members of the aircraft.
Fairleads should never de-flect the alignment of a cable more than 3' from a straight line.
Pressure seals
1.PRESSURE SEALS ARE INSTALLED WHERE CABLES (OR
RODS) MOVE THROUGH PRESSURE BULKHEADS.
2. THE SEAL GRIP TIGHTLY ENOUGH TO PREVENT EXCESS AIR PRESSURE LOSS
BUT NOT ENOUGH TO HINDER MOVEMENT OF THE CABLE.
3. PRESSURE SEALS SHOULD BE INSPECTED AT REGULAR INTERVALS TO

DETERMINE THAT THE RETAINING RINGS ARE IN PLACE. IF A RETAINING RING
COMES OFF, IT MAY SLIDE ALONG THE CABLE AND CAUSE JAMMING OF A
PULLEY.
CONTROL (PUSH-PULL) RODS,
1. CONTROL RODS ARE USED AS LINKS IN FLIGHT CONTROL SYSTEMS TO GIVE A PUSH-
PULL MOTION.
2. THEY MAY BE ADJUSTED AT ONE OR BOTH ENDS. VIEW A OF FIGURE SHOWS THE
PARTS OF A CONTROL ROD.
3. IT CONSISTS OF A TUBE HAVING THREADED ROD ENDS. AN ADJUSTABLE ANTIFRICTION

ROD END, OR ROD END CLEVIS, ATTACHES AT EACH END OF THE TUBE.
THE ROD END, OR CLEVIS, PERMITS ATTACHMENT OF THE TUBE TO FLIGHT CONTROL
SYSTEM PARTS. THE CHECK NUT, WHEN TIGHTENED, PREVENTS THE ROD END OR CLEVIS
FROM LOOSENING.
Measuring Cable Tension
 To determine the amount of tension on a cable, a tensiometer is
used.
 When properly maintained, a tensiometer is 98% accurate.
 Cable tension is determined by measuring the amount of force
needed to make an offset in the cable between two hardened steel
blocks, called anvils. A riser or plunger is pressed against the cable to
form the offset.
Several manufacturers make a variety of tensiometers, type
designed for different kinds of cable, cable sizes, and cable tensions.
One type of tensiometer is illustrated in figure 2-64.. With the
trigger lowered, place the cable to be tested under the two anvils.
Then close the trigger (move it up). Movement of the trigger
pushes up the riser, which pushes the cable at right angles to the
two clamping points under the anvils.
The force that is required to do this is indicated by the dial pointer.
As the sample chart beneath the illuatration shows, different
numbered risers are used with different size cables.
Each riser has an identifying number and is easily inserted into the
tensiometer.
Continue….
In addition, each tensiometer has a calibration table (figure 2-64)
which is used to convert the dial reading to pounds.
(The calibration table is very similar to the sample chart shown

below the illustration.)
The dial reading is converted to pounds of tension as follows. Using

a No. 2 riser (figure 2-64) to measure the tension of a 5/32-in.
diameter cable a reading of "30" is obtained.
The actual tension (calibration table) of the cable is 70 lbs.

Observing the chart, also notice that a No. 1 riser is used with 1/16..
3/32-, and 1/8-in. cable.
Calibration table
Continue
Since the tensiometer is not designed for use in measuring 7/32-
or 1/4-in. cable, no values are shown in the No. 3 riser column of the
chart.
When taking a reading, it may be difficult to see the dial.

Therefore, a pointer lock is present on the tensiometer. Push it in to
lock the pointer.
Then remove the tensiometer from the cable and observe the
reading. After observing the reading, dull the lock out and the
painter will return to zero.
Continue……
Cable rigging tension charts (figure 2-65) are graphic tools used
to compensate for temperature variations.
They are used when establishing cable tensions in flight control
systems, landing gear systems, or any other cable-operated
systems.
To use the chart, determine the size of the cable that is to be
adjusted and the ambient air temperature.
For example, assume that the cable size is 1/8-in. in diameter,
that it is a 7 x 19 cable, and the ambient air temperature is 85" F.
Follow the 85' F. line upward to where it intersects the curve
 for 1/8-in. cable. Extend a horizontal line from the point of
intersection to the right edge of the chart.
 The value at this point indicates the tension (rigging load in
pounds) to establish on the cable. The tension for this example is
70 lbs.

Aircraft Control Cable

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Aircraft Control Cable

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Aircraft Control Cable

Aircraft Control Cable

7 x 19 7x7 3x7 1 x 19 1x7

TURN BUCKLE: # A TURNBUCKLE ASSEMBLY IS A MECHANICAL SCREW DEVICE

WHEN INSTALLING A TURNBUCKLE IN A CONTROL SYSTEM, IT IS NECESSARY TO

IT IS ALSO ESSENTIAL THAT ALL TURNBUCKLE TERMINALS BE SCREWED INTO THE

A bell crank is used to transmit force and permit a change in the

3. PRESSURE SEALS SHOULD BE INSPECTED AT REGULAR INTERVALS TO

3. IT CONSISTS OF A TUBE HAVING THREADED ROD ENDS. AN ADJUSTABLE ANTIFRICTION

(The calibration table is very similar to the sample chart shown

The dial reading is converted to pounds of tension as follows. Using

The actual tension (calibration table) of the cable is 70 lbs.

When taking a reading, it may be difficult to see the dial.

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