EASA B1.1 : MODULE 6.

10

Control Cables

22/03/22
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 Control Cable and Fitting

Cables
 
Cables provide a strong, light and flexible method of control and are used
extensively in aircraft control systems. Cables operate in tension and can
therefore, only be used to pull the control.

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CONTROL CABLES

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Construction
 
Flying control cables are normally preformed; that is, the strands in the cable
are formed into the shape they will assume in the complete cable. The cables
which are made of galvanised or corrosion-resistant steel are impregnated with
a friction-preventative lubricant during manufacture.

There are a number of advantages to be derived from the use of the preformed
type e.g. the cables resistance to unstranding is improved by a twisting action
applied to the individual strands during manufacture, they are non-kinking and
have no high strands. In addition, should a wire become broken, it will tend to
lie flat and therefore will be less hazardous. 

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Construction

Both commercial and aircraft wire cables are further identified by the number
of strands and the number of wires in each strand. Aircraft cables may be of
the flexible type (7x7) or extra flexible type (7x19), extra flexible wire cable,
there are a greater number of wires per strand, so the individual wires are much
finer, the smallest diameter for extra-flexible cable is 1/8", because below this
the individual wires would be too fine.

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A cable is made up of steel wires which, in turn, are formed into strands,.

Each strands consists of several wires (7 or 19) which are wound helically in one or
more layers, the center wire being known as the core wire or king wire.

Each cable is made up of several strands (usually 7,) wound helically around the
center or core strand. The cable is described by the number of strands it contains
and by the number of individual wires in each strand.
 
 

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The number of wires in each strands, the number of strands, and the
overall diameter of the cable determine the breaking load of the cable.

For example, a 7 x 19 cable of 6.4mm (1/4in) overall diameter has a

minimum breaking load of 7000 lbf.

Cables are classified either by the minimum breaking load, which may be
quoted in cwtf, lbf or kN, or by the nominal diameter in inches.
 

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Prepared By: M.Azlan Shafie
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 wire are pre-formed into a helical or spiral shape and then joined into a
strand.
These preformed strands are laid around a straight centre strands to form a cable.

 Cable designations are based on the number of strands and the number
of wire in each strand.
 The most common aircraft cables are the 7 x 7 and 7 x 19.

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 Cable Strands

This cables is extra flexible and is used in primary control systems

and in other places where operation over pulleys are frequent.

Aircraft control cables vary in diameter, ranging from 1/16 to 3/8

inch. The diameter is measured as shown in the figure 1.
 

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 Figure 1:
Most Common
Aircraft Cables
(7x7) & (7x19)

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Cable Fittings

The threaded end, fork end and eye end terminals are used to connect the cable
to a turnbuckle, ball crank or other linkages in the system.

 The ball-end terminals are used for attaching cables to quadrants and
special connections where space is limited.

 Figure 2 illustrates the various types of terminal fittings.

The thimble, bushing and shackle fittings may be used in place of some type of
terminal fitting when facilities and supplies are limited and immediate
replacement of the cable is necessary.
 Figure 2:
Various type of
terminal fittings
 NICOPRESS

Nicopress® process—a patented process using copper sleeves and may be used up to the full rated
strength of the cable when the cable is looped around a thimble figure below.

This process is used for cable splicing, it is imperative that the tools, instructions, and data
supplied by Nicopress® be followed exactly to ensure the desired cable function and strength is
attained.

The use of sleeves that are fabricated of material other than copper requires engineering approval
for the specific application by the Aviation Authority.
SWAGING
 
The cables used in flying control and other cable-operated systems are usually manufactured
from preformed steel wire rope with swaged cable end assemblies.

Swaging is an operation in which a malleable end fitting is secured to the end of a cable by
plastic deformation of the hollow shank of the end fitting.

The end of the cable is inserted into the hollow shank of the fitting which is then caused to grip
the cable by squeezing or hammering the shank in a swaging machine.

Manufacturers of made-up cables normally swage with rotary machines in which the shank of
the end fitting is placed between suitable dies and subjected to a succession of forming blows
which reduce the diameter of the shank and so lock the fitting to the cable.
CABLE SWAGING MACHINE
 Control Cable End Fittings

Cable end fittings in use today are

shown in figure 3

After the fitting is swaged on

It is checked with a go no-go gauge to

ensure that the swaging has came out
properly.

Figure 3:
Some of the cable fittings are Cable end fitting
checked with a go no-
turnbuckles and shackle pins.
go gauge
 Control Cable Inspection

Aircraft cable systems are subject to a variety of environmental conditions and

deterioration. Wire or strand breakage is easy to recognize visually.

Other kinds of deterioration, such as wear, corrosion, and distortion, are not easily
seen. Special attention should be given to areas where cables pass through battery
compartments, lavatories, and wheel wells. These are prime areas for corrosion.

Special attention should be given to critical fatigue areas. Those areas are defined as
anywhere the cable runs over, under, or around a pulley, sleeve, or through a fairlead;
or any section where the cable is flexed, rubbed, or within 1 foot of a swaged-on
fitting.

Close inspection in these critical fatigue areas can be performed by rubbing a rag
along the cable. If there are any broken strands, the rag snags on the cable. A more
detailed inspection can be performed in areas that may be corroded or indicate a
fatigue failure by loosing or removing the cable and bending it. This technique
reveals internal broken strands not readily apparent from the outside. [Figure 8]
 Control Cable Inspection

Close inspection in these critical fatigue areas can be performed by rubbing a rag
along the cable. If there are any broken strands, the rag snags on the cable. A more
detailed inspection can be performed in areas that may be corroded or indicate a
fatigue failure by loosing or removing the cable and bending it.

This technique reveals internal broken strands not readily apparent from the outside
as shown figure below.
 TURNBUCKLES

A turnbuckle assembly is a mechanical screw device that consist of two

threaded terminals and a threaded barrel.

Figure 4 illustrate a typical turnbuckle assembly.

Turnbuckles are fitted in the cable assembly for the purpose of making minor
adjustments in cable length and to adjust cable tension.

One of the terminals has right-handed threads and the other has left-handed
internal threads.

The end of the barrel with the left-handed threads can usually be identified
by a groove or knurl around the end of the barrel.
 Figure 4:
A typical turnbuckle assembly
TENSION ROD TYPE
 Pulley

 In a flight control system, pulleys are used to:

i. change the direction of operation of the control cables.

ii. give support on long straight runs of the cable.

Aircraft pulleys are manufactured from various materials,

 such as aluminium alloy, Teflon, fluorocarbon resins, phenolic and
other plastic materials.

• The pulleys bearings are usually of the sealed type and require no
lubrication.

• The pulley is bounded to the bearings in such a manner that the bearing
cannot be removed.
 Fairlead

Fairleads 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 structural members of
the aircraft.

Fairleads should never deflect the alignment of a cable more than 3° from a straight line.
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Pulley

A cable guide (or Retainer) is fitted to the pulley to ensure that the
cable remains on the pulley.

When adjusting a control, it is important to ensure that the cable end fittings
do not foul the pulley; otherwise the cable movement will be restricted.

Also look for possible misalignment between the cable and pulley; this must
not exceed 2°.
 Cable tension
For the aircraft to operate as it was designed, the cable tension for the flight controls must be
correct. To determine the amount of tension on a cable, a tensiometer is used. When properly
maintained, a tensiometer is 98 percent 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, each type designed for different kinds of cable, cable sizes, and
cable tensions as shown figure below.

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 Tension Regulators

Cable tension regulators are used in some flight control systems because there is
considerable difference in temperature expansion of the aluminum aircraft structure and the
steel control cables.

Some large aircraft incorporate tension regulators in the control cable systems to maintain
a given cable tension automatically. The unit consists of a compression spring and a
locking mechanism that allows the spring to make correction in the system only when the
cable system is in neutral.
 Inspection and Maintenance of Pulley

All pulleys in a flight control system should be examine or check for wear, cracks
and alignment.

If a pulley is worn or cracked to an appreciable extent, it should be replaced.

The pulleys should turn freely when the control cables are moved.

If a pulley is out alignment, it will cause wear to both the pulley and the cable.
 
 
The mountings for such pulleys should be corrected and the
cable carefully examine for wear.

Typical pulley wear patterns are shown in figure 5.

Avoid contamination between pulleys and harmful substances

such as hydraulic fluid, aircraft fuel, paint stripper, etc.
 Figure 5:
Typical pulley wear patterns

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 Bowden Cable

Cable

Short run, lightly loaded type and made of non - corrodible steel wires.

Designed for "PULL" operation only.

Bowden control cable consists of: -

1. Cable 2. Conduit
3. Cable Nipples 4. End Fittings

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 Bowden Control System Components

There are relatively few component parts to a Bowden Control System.

Each system is, however, designed to meet a particular requirement, and hence may differ
in detail from the basic control, whilst retaining the functional characteristics of the basic
system
 
These components are: -

i. Hand Lever – Located in aircraft cockpit

ii. Plain Adjustment Stop – Fitted to the control at the receiving end of the cable.
iii. Double Ended – To fit a plain adjustment stop to a Bowden control.
iv. Junction Box – Used to connect a single cable to two or more cable.
PLAIN O PERATIN G LEVER

DO UBLE ENDED STO P

LEE-BARREL LEVER

ADJUSTABLE STOP
LO CKNUT
AIRC RAFT STRUCTURE
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 Aircraft Flexible Controls

1. Bowden Controls

The Bowden Controls system works only in tension.

The control is intended for 'pull' operation only, the cable being returned,
on release of the control lever, by a spring.

Operate trimming tabs, aircraft's flying control surfaces, apply brakes,

control fuel cocks and other controls associated with the aircraft engines.
2. Teleflex Controls

Controls operated from the cockpit.

Provides a more accurate and positive control throughout the range of

movement and can be temporarily locked in any desired position.

Operating components are engine and propeller controls, trimming

controls and fuel valves, indication of landing gear movements and the
position of flaps.

Consists of flexible, transmitting cable, operating inside rigid or flexible

metal conduit.

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3. Chain Controls
 
Provide a flexible, strong and positive connection and is used to change
the direction of pull in control runs where considerable force is exerted.

Control aileron, elevator, trimming tab and engine controls.

Comprises of sprocket, steel rod or cables.

 

Prepared By: M.Azlan Shafie