CONTROL CABLES

CONTROL CABLES AND TERMINALS

 Cables are 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.

 Aircraft control cables are fabricated from carbon

steel or stainless steel.
Advantages:

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 very important for precise control.
Disadvantage :

 Tension must be adjusted frequently due to

stretching and 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 a cable.
 Cable designations are based on the number of strands
and the number of wires in each strand.
CABLE CONSTRUCTION
 The most common aircraft cables are the 7 × 7 and 7 × 19.

 The 7 × 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.

 The 7 × 19 cable is made up of seven strands of 19 wires each. Six

of these strands are laid around the center strand.

 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 1⁄16 to 3⁄8 inch.
CABLE FITTINGS
 End fittings:
 terminals, thimbles, bushings, and shackles.

 Terminal fittings are generally of the swaged type.

 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.
TURNBUCKLES
A turnbuckle assembly is a mechanical screw device
consisting of two threaded terminals and a threaded
barrel.

 As shown in diagram 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.
TURNBUCKLES

 The barrel has matching right- and left-hand

internal threads.

 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.
TURNBUCKLES
 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 safe
tied.
TURNBUCKLES
PUSH-PULL TUBE LINKAGE
 This type linkage eliminates the problem of varying
tension and permits the transfer of either
compression or tension stress through a single
tube.
 A push-pull tube assembly consists of a hollow
aluminum alloy or steel tube with an adjustable
end fitting and a checknut at either end.
 The check nuts secure the end fittings after the
tube assembly has been adjusted to its correct
length.
 Push-pull tubes are generally made in short
lengths to prevent vibration and bending under
compression loads.
 CABLE SYSTEM COMPONENTS
•Turnbuckles
•Used in cable control systems to adjust cable
tension.
•The turnbuckle barrel is threaded with left-hand
threads inside one end and right-hand threads inside
the other.

•Cable Connectors
•In addition to turnbuckles, cable connectors are
used in some systems.
•These connectors enable a cable length to be
quickly connected or disconnected from a system.
•This type is connected or disconnected by
compressing the spring.
CABLE SYSTEM COMPONENTS
•Gust lock
•A cam on the control quadrant shaft engages a spring-
loaded roller for the purpose of centering and neutralizing the
controls with hydraulic system off (aircraft parked).
•Pressure is trapped in the actuators and since the controls
are neutralized by the cam and roller, no movement of the
control surfaces is permitted.

•Cable guides
•Cable guides consist primarily of fairleads, pressure seals,
and pulleys.
 CABLE GUIDES
Fairlead
•Made from nonmetallic material, such as Phenolic or a metallic
material such soft aluminium.
•Completely encircles cable where it passes through holes.
•used to guide cables in a straight line through or between
structural members of the aircraft.
•never deflect the alignment of a cable more than 3mm from a
straight line.

Pressure seals
•Installed where cables (or rods) move through pressure
bulkheads.

Pulleys
•Used to guide cables and also to change the direction of cable
movement.
 MECHANICAL LINKAGES
•The linkage consists primarily of control (push pull) rods, torque
tubes, quadrants, sectors, bell cranks and cable drums.
•Control rods are used as links in flight control system to give a
push-pull motion.
•They may be adjusted at one or both ends.
 Torque tubes
•Where an angular or twisting motion is needed in control system,
a torque tube is installed.
•Quadrants, bell cranks, sectors, and drums change direction of
motion and transmit motion to parts such as control rods, cables
and torque tubes.
•Cable drums are used primarily in trim tab system.
•As the trim tab control wheel is moved clockwise or counter
clockwise, the cable drum winds or unwinds to actuate the trim
tab cables.
 Control (Push Pull) Rods

Control (Push Pull) Rods & Bell Crank

BOWDEN CABLES
•A Bowden cable is a type of flexible cable used to transmit mechanical
force or energy by the movement of an inner cable (most commonly of
steel or stainless steel) relative to hollow outer cable housing.
•The housing is generally of composite construction, consisting of helical
steel wire, often lined with plastic, and with a plastic outer sheath.
•Usually provision is made for adjusting the cable tension using an inline
hollow bolt (often called a ͞barrel adjuster͟), which lengthens or shortens
the cable housing relative to a fixed anchor point.
•Lengthening the housing (turning the barrel adjuster out) tightens the
cable; shortening the housing (turning the barrel adjuster in) loosens the
cable.
CABLE ASSEMBLY INSPECTION
•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
its extreme travel limits.
•This will reveal the cable in pulley, fair lead, 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.
•If there is no internal corrosion, remove external corrosion
with a coarse weave rag or fibber brush.
•Never use metallic wools or solvents to clean flexible cable.
•Control cables and wires should be replaced if worn,
distorted, corroded, or otherwise damaged.
•Special attention should be given to areas where cables pass
through battery compartments, lavatories, and wheel wells.