Summary of Annotations

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flexible control cables are by

far the most commonly used method

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Cables are used in pairs and are stretched taut

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very little play is

present in system controls

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no lost motion exists between

the actuating device and the unit

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In some simple cable systems, only one

cable is used, and a spring provides the return action

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Cables can be installed over long distances (such as in

large aircraft) without a great degree of sagging or bending

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(such as in

large aircraft)

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Cables are stronger than steel rods or

tubing of the same size

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They flex without setting (permanent

deformation) and can be led easily around obstacles by using

pulleys

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two cables always needed in a system to

transmit signal in two directions

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disadvantage of a cable

system for control movement relates to thermal contraction

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the aluminum structures

contracts much more than the small mass of steel in a control

cable, and as a result, cables lose their tension

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The basic element of a cable is strand

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number of strands

are braided together to form a wire

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number of wires are

braided together to form a cable

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The direction of the twist of strands and the twist of wire could

be either in the same direction or to the opposite direction. The

later one has the tendency of resisting uncoiling of wires and

strands together when the cable is twisted in one direction and

also the strands are less stressed, because when the wires are

twisted on the opposite direction, the strands are reset.

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This opposite direction twist, which is most commonly adopted,

called a regular or an ordinary lay

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If the strands are twisted in the

direction of twist around the centre strand or core, the lay is

called a lang lay

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twisting the strands alternately right and left,

then twisting them all either to the right or to the left about the

core is called a reverse lay

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Most aircraft cables have a right

regular lay

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The process of pre-forming is adopted to

ensure flexibility in the finished cable and to relieve bending and

twisting stresses in the strands as they are woven into the

cable

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It also keeps the strands from spreading when the cable

is cut

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The small corrosion-resistant

steel cables are made of steel containing not less than 17

percent chromium and 8 percent nickel

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the larger ones

(those of the 5/16-, 3/8-, and 7/16-inch diameters) are made of

steel that, in addition to the amounts of chromium and nickel

just mentioned, also contains not less than 1.75 percent

molybdenum

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Cables are designated according to the number of wires in a

cable and number of strands in a wire

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A 7 x 7 cable consists of six strands of seven

wires each, laid around a centre strand of seven wires

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A 7 x 19

cable consists of six strands of 19 wires, laid around a 19-wire

central strand

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A 6 x 19 cable consists of six strands of 19 wires

each, laid around an independent wire rope centre

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Flexibility

depends on the number of strands for cable with a given

diameter

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In areas where a linkage does not pass over any pulleys,

nonflexible cable can be used

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The 1 x 7 cable is made up of
one strand comprised of seven individual wires

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the 1 x

19 consists of one strand made up of 19 individual wires

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Nonflexible cable is available in both galvanized carbon steel

and stainless steel

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Flexible steel cable made up of seven strands of seven wires

each is called 7 x 7 or flexible cable (refer fig. 01), and is

available in 1/16 and3/32 inch sizes in both galvanized carbon

steel and stainless steel. Both types are preformed

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The most widely used cable, 7 x 19, (refer fig, 01) is available in

sizes from 1/8inch up

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made of 133

individual wires wound in seven strands, each strand having 19

wires
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Galvanized cable is more

resistant to fatigue than stainless steel

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in applications

where corrosion is a factor, stainless steel is used

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just mentioned

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Lock clad cable is used on some large aircraft for all long,

straight runs

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Changes in tension

due to temperatures are less than with conventional cables,

also the amount of stretch at a given load is less

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Aircraft control cables vary in

diameters, ranging from 1/16 of an inch to 3/8 of an inch

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Terminal fittings are generally of the swaged type

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The ball terminals are used for attaching cable to

quadrants and special connections where space is limited

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Threaded-end, fork-end, and eye-end terminals are used to

connect the cable to turnbuckles, bell cranks, and other linkage

in the system

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The

single-shank ball end is usually used on the ends of cables

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double-shank ball end may be used at either the ends or in

the centre of a cable run

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Thimble and bushing 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

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A turnbuckle is a mechanical screw device consisting of two

threaded terminals and a threaded barrel

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Turnbuckles are fitted in the cable assembly for the purpose of

making minor adjustments in cable length and for adjusting

cable tension

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When you install a turnbuckle in

a control system, it is necessary to screw both of the terminals

an equal number of turns into the turnbuckle barrel

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On initial

installation, the turnbuckle terminals should not be screwed

inside the turnbuckle barrel more than four threads

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all turnbuckle terminals be screwed into the barrel

at least until not more than three threads are exposed

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Lock clip is a bent metal pin

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Note: do not reuse lock clips after removal

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Of the methods using safety wire for safetying turnbuckles, the

double wrap method is preferred

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After safetying, no more than three threads of the
turnbuckle-threaded terminal should be exposed

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Insert wire through hole, make approximately six twists, and cut

excess of wire, bend twisted end flat along side of pulley.

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Guard pins are installed in the flanges of pulley brackets to

prevent the cable from jumping out of the pulley

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A guard pin can be either a bolt or a clevis pin

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Fairleads (rub strips), grommets, pressure seals, and pulleys

are all types of cable guides

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In no case should the fairlead be permitted

to deflect a cable more than 30

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Grommets are made of rubber, and they are used on small

openings where single cables pass through the walls of

unpressurized compartments

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Control cable Pressure Seals are installed where cables route

from a pressurized to a non-pressurized area

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The seals are mould of synthetic

or silicon rubber, which are ozone resistance

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Pressure Seal normally

do not need lubrication

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The silicone

rubber seals are less susceptible to damage caused by bushing

pop out, cleaning abuse and aging

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Split fairleads are made for easy

installation around single cables to protect them from rubbing on

the edges of holes

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Most pulleys

used on aircraft are made from layers of cloth impregnated with

phenolic resin and fused together under high temperatures and

pressures

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

direction of the force and also use as the interface between

cable system and rigid control systems

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Pulleys (or sheaves) are grooved wheels used to change cable

direction and to allow the cable to move with a minimum of

friction

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A quadrant, shown above is often employed at the base of a

control column or control stick to impart force and motion to

cable system

#2 StrikeOut (Shabbir)

, shown above

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Sectors and quadrants are also used as the interface

of cable to rigid control systems

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This

results in a lower and more nearly constant control system

function with subsequent increase in cable fatigue life and

decrease in cable wear

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The cable tension regulator is used in control systems to

mechanically compensate for effect of relative length change

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the

quadrant moves through a relatively small arc, perhaps as low

as 1000

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To determine the amount / load of tension on a cable, a

tensiometer is used

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Cable tension is determined by measuring

the amount of force needed to make an offset in the cable

between two steel blocks, called "anvils"

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To use a

tensiometer a cable is placed between the two blocks on the

frame and the riser

Page 17

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The Bowden-type control consists of a stainless steel wire

housed in a flexible sleeve, or conduit

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The control is intended

for `pull' operation only, the cable being returned, on release of

the control lever, by a spring

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it is capable of transmitting both push and

pull motion through a single cable

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Its main advantages over

the Bowden system are that it provides a more accurate and

positive control throughout the range of movement and

furthermore, that the controlled component can be temporarily

locked in any desired position

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The cable consists of a high tensile steel core around which is

wound either a left-hand or right hand helix wire

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There are two types of Teleflex cable

in current use the DS23/2 (or No 2) and the DS 380, one being

much stronger than the other

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A cable-operated trimming tab control system usually operates

a screw jack at the receiving end of the system