MATERIALS AND HARDWARE 6.10 - Control C les End fittings, turnbuckles and compensation devices Pulleys Bowden cables, les Types of ea cable system components Aircraft flexible control systems, Levelt A uilaiation wit he principal clmenrs ofthe subject. (@) The aplicane shoul be familar with the bas lens ofthe abe (8) Treapplicat shold be abeto give imple description ofthe whole bjec using common werds and example. (© Theaprlicant should be abl owe typical terms Module 06 - Materials and Hardware CONTROL CABLES SUB-MODULE 10 PART-66 SYLLABUS LEVELS Bi B2 Level? A general knowlalge ofthe theoretical and practice apecte of the subject sod an aby to apply that know jecivs (4) The applicant shouldbe blero understand the theoretical fundamentals cf the tect. (©) Theapplicane shouldbe able w give general description of the subject using, a appropri, yp example, (© Theapplicant should be abl to ie materarl fora tion with py aws desing the subject beable wo real and derstand etch, tics deserting dhe sje icant should be able to ppl his knowledge in a practical ing deta pocedires 40.1 CONTROL CABLESCONTROL CABLES AND TERMINALS Cables are the most widely used linkage in primary flight control systems. Cable-type linkage is also used in engine controls, emergency extension systems for the landing gear, and various other systems throughout the aircraft. Cable-type linkage has several advantages over the other types. It is strong and light weight, and its flexibility makes it easy to route through the aircraft. An aircraft cable has a high mechanical efficiency and can be set up without backlash, which is veryimportant for precise control. Aircraft control cables are fabricated out of carbon steel or stainless steel. A disadvantage of cable linkage is that tension must be adjusted frequently. This is due to stretching as well as expansion and contraction due to temperature changes: CABLE CONSTRUCTION “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 2 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 7x 7 and 7 19, ‘V0 16 Daneter? 19 16-9792 ameter? «7 10.2 “The 7 x 7 cable consists of seven strands of seven wires each. Six of these strands are laid around the center strand, (Figure 10-1) This isa cable of medium flexibility and is used for trim tab controls, engine controls, and indicator controls. The 7 x 19 cable is made up of seven strands of 19 wices each. Six of these strands are laid around the center strand. (Figure 10-1) “This cable is extra flexible and is used in primary control systems and in other places where operation over pulleys. is frequent. Aircraft control cables vary in diameter, ranging from “As to inch, The diameter is measured as shown in Figure 10-1. CABLE FITTINGS Cables may be equipped with several different types of fittings, such as terminals, thimbles, bushings, and shackles. ‘Terminal fitings 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 tumbuckle, bellcrank, or other linkage in the system. Ihe ball end terminals are used for attaching cables to quadrants and special connections where space is limited. Figure 10-2 illustrates the various types of terminal fittings. 7 Stands 19 Wes ‘sans, 7 wires to eseh Stand Module 06 - Mattils and Hardware‘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. ‘A668 ole Shank Bal nd Terra mm, — ‘65 Sina Sank Bal nt Torin ——_* : ANGES Rod End Terminal en N66 Toad Cable Torna 6s Ey Ent Cable Terral Figure 10-2. Types of terminal tings. CABLE SYSTEM INSTALLATION CABLE GUIDES 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. Pulleys should be examined to ensure proper lubrication; smooth rotation and freedom from abnormal cable ‘wear patterns which can provide an ini problems in the cable system. (Figure 10-3) Module 06 - Material and Hardware Figure 10-2, Pulley wear patterns 10.3 CONTROL CABLES