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EIA-EXSAL 3. Structure of the cell-aircraft Modified by TMA Jaime Ortiz

3
 6.10-Control cables

6.10 Control cables

Types of Cables;
,

hardware, Poleasy
compensation devices, the
cable transmission system
components: Bowden
Type Cables;
* Flexible aircraft control systems. of
Anvil terminal stamping;

Inspection and testing of control cables;

4
EIA-EXSAL 6.10- . Control Cables Prepared by TMA Jaime Ortiz
 GOALS :
Upon completion of this section you will
be able to:
■ describe the different
types of swaged fitting
(accessory
stamping) in aviation

5
EIA-EXSAL 6.10- . Control Cables Prepared by TMA Jaime Ortiz
 ■usedListin airplanes.
the types of flexible cables

6
EIA-EXSAL 6.10- . Control Cables Prepared by TMA Jaime Ortiz
 • Currently
• FLIGHT CONTROL CABLES

Elevators

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 TYPES OF
CABLES compensat
or
9
elevator
s to
r
p u
el ac 1d
o
i evator tu d
at
l / de
e elevat or r
joystick t
r or trim c
c
pedals contro o
m r
l delk l
pe u
cont i rudder
rudder ns d
rol m
at cables d
cabl e
e or depth e
balance rudder cables
of r r
cable
the i
ddb
spoi
spoiler
o
ler
d
r e
t p
e t
n h
s
i
o port aileron^i^;-^
n
e
r
s
 • Many aircraft controls are actuated by
cables through the airframe. The direction
of a cable changes as it passes through a
turnbuckle, and the cable is held isolated
from the structure by means of fairleads.
• Control cables are made of corrosion-
resistant preformed steel or pre-
galvanized steel. formed. There are three
basic types of cables, and their use
depends on the type of installation.

9
EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
 • These types are :
• non-flexible,
• flexible, and
• extra-flexible.
• The flexible cable, called 7x7, is mainly
used for motor controls and “Trim Tab”. It
can change its direction by means of tie
rods, but is not subject to extreme bending
as exists in primary control systems.

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0
EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
 • EXTRA-FLEXIBLE CONTROLCABLE:
• Primary control systems are normally handled by
extra cables flexibles made of 7 strips, each
containing 19 individual wires. These cables are
made in such a way that they do not disperse
when cut to attach terminals.
• CONTROL CABLES FOR AIRCRAFT
• NON-FLEXIBLE CONTROL CABLE
• FLEXIBLE CONTROL CABLE
• EXTRA FLEXIBLE CONTROL CABLE
• TERMINALS FOR CONTROL CABLES
• TENSIONERS
9

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 A 1 x 7 Nonflexible B 1 x 19 Nonflexible C 7 x 7 Flexible D 7 x 19 Extra
control cable control cable control cable flexible control
cable
Cable control

10

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 • Forms of construction

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 FINAL HARDWARE AND COMPENSATION DEVICES

Almost all cables installed on modern aircraft have swagged

terminals.

These terminals are made of stainless steel and have a hole where the
cable is placed to be swagged using a specific tool for this task.

A properly swagged terminal has the full strength of the cable.

• To determine if a control cable is properly installed, it must be measured both before and after
swagging.
 • Before installing the terminal, its diameter must be
large enough to not pass through the gage hole. After swaging,
the diameter must be reduced so that it passes through the gage
hole.
• The control cables in
some small aircraft and
Older models use “Thimble” type
eye terminals.
• When installing a fitting of this type,
a copper coating must be placed on
the end of the cable so that it is
inside the eye of the terminal.

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

Swaging of end fittings

Stamping type Terminals,

manufactured to AN and
MS standards, are
available for use on civil
aircraft and this includes
maximum cable loads.
 STAMPING FINAL HARDWARE

> When using tools for swaging it is

important that all manufacturer's
instructions, including the “go” and “no
go” dimensions, are followed in detail to
avoid defective and low-quality swaging.
> Taking all instructions into account will
result in a terminal with high resistance.

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8
EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
 17

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 Critical dimensions for before and after swaging are
shown in the following table:

TABLE 7-5. Straight- shank terminal dimensions. (Cross reference AN to MS: AN-666 to MS 21259. AN-667 to MS 20667, AN-668
to MS 20668. AN-669 to MS 21260.)
Before swaging After swaging
Minimum
Cable size Outside breaking Shank
Wire strands Bore diameter bore length Swaging length
(inches) diameter strength diameter *
(pounds)

1.042 480
1.261 0.969 920
1.511 1.188 2,000
7x7 1.761 1.438 2.800
0.160 0.078
7x7 2.011 1.688 1.938 4,200
213 .250 109 141 0.138 .190
2.261 5,600
1/16 3/32 7x19 7x19 7x19 297 .359 172 .203 2.188 2438 .219 .250
7x19 2.511 7,000
1/8 5/32 3/16 .427 .494 .234 .265 2.688 .313 .375
7x19 7x19 7x19 2.761 8,000
7/32 1/4 .563 .635 .297 2.938 .438 .500
7x19
3.011 9,800
9/32 5/16 3/8 .703 328 .390 3.438 .563 .625
3.510 14,400
'Use gauges In kit lor checking diameters.

18

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 Terminals
Procedures for
print:
1- Cut the cable to the appropriate length for
swaging.
Note; Never solder the end of the cable to avoid
fraying, this makes the cable tend to come out of the
terminal.
2- Insert the wire into the terminal about an inch
and bend it against the terminal, then push the wire
into the terminal. The bending action provides
enough friction to keep the terminal in place.
19

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

Procedure for swaging:

3- perform the swaging operation according to

the manufacturer's instructions 5 - using a “go no go” gauge or a micrometer, check the
diameter of the terminal stem.
4- Inspect the terminal after swaging to determine
that it is free of marks and cuts and that it is also not
round.

Check for cable slipping out of the terminal and for

cuts or breaks in the cable.
 Procedure for swaging:
6 - Test the cable for
loads at 60%
breaking strength.

2
3
EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
ball terminals
• In some aircraft cables, wire cables are used.
ball for joining cables to quadrants and connections
special ones where space is limited.
V Terminals of simple stem are generally
used in the cable ends and fittings
Double shank can be used either at the end or in the center of the cable.
V Dies are supplied with the swaging machines to join the terminals to the cables using the
following method:

2
4
 Procedure
1- The steel balls and stems have a hole in the center and are slid over the
cable and positioned in the desired location.

2- Perform the swaging operation in accordance with the equipment

manufacturer's instructions.

3 -check the fitting with a “go” no-go” gauge to see that the fitting is properly
compressed and inspect the
physical condition of the finished terminal.

23
EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
 CABLE SLIP IN THE TERMINAL

• Make sure the cable is properly inserted into the terminal after swaging. It is known that in some cases only a
quarter of an inch has entered the terminal.

• Let us observe the following precautions to minimize this possibility:

• 1 - Measure the length of the terminal to determine the length

of the cable to be inserted.

• 2 - Place the cable next to the fitting, mark it with a pull

to do the swaging.

• 3 - After swaging check the shot mark to

Make sure there is no slippage during operation. 24

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

4- Remove the tape and paint the fitting and cable joint with red paint.

5- At all subsequent maintenance services, inspect for gaps or space in the painted part, if so, this will indicate
that the cable has slipped.
 TENSIONERS

• The tension of a control cable is adjusted using

TENSIONERS (Turnbuckles).

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 TENSIONERS
• The bronze barrel has a right-hand thread on one side and a left-hand
thread on the other. The cable terminals are screwed into the barrel
and as it rotates, both cables are pulled towards each other.

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 TENSIONERS
• To ensure that the terminals are threaded into the barrel enough to
produce maximum force, there should be no more than three strands of
wire.
exposed on both sides of the barrel.

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 TENSIONERS
• When the tension of a cable is properly adjusted,
secure the tensioner with one of the methods
following:
Four turns minimum
This applies to all turnbuckle wrapping.

Double-wrap spiral

Double-wrap

Single-wrap spiral

Single-wrap

Turnbuckle safeiy'ing methods

 TENSIONERS
• Some tensioners are made for special fixing devices. Cable tension is
adjusted with the tensioner, and secured by inserting the MS21256
terminal tab into the internal slot inside the barrel at the end
of the terminals.
 Proof testing

* When new cables are made using nicopress or

swaged terminals, the cables must pass a proof test
or load test.

❖ This is done by slowly placing a load of up to 60% of the breaking strength

of the cable. Once this charge is obtained, it must be maintained for 3 to 4
minutes.

❖ Special equipment is required to do this test and it must be completely safe

to operate since a cable under several tons of pressure can cause a lot of
damage if it fails.

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3
EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
 Bowden Type
•
Cables
The Bowden Cable , guaya or chicote, is a type of flexible mechanical cable used for the mechanical
transmission of movement. by traction, for it
It has an internal flexible cable, which transmits movement, surrounded by a shirtprotective
also flexible, which serves as a support point to transmit the effort to the final end of the cable.
• They are mainly used for elements mounted on supports subject to movement, such as the engine (which
oscillates on the silent-blocks) or the wheels; for example, the accelerator control, the handbrake, the clutch, the
vehicle's internal heating, etc.

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

Bowden controls are also used to regulate the movement of elements linked on parts fixed to each other, but in
positions for which it is difficult or not convenient to carry out other types of union or mechanical coupling; for
example: the controls for opening the engine hood and luggage rack, the filler neck, etc.

3
5
 • Flexible controls are very versatile, have no play and are
much more economical than rigid rod systems.
However, a series of precautions must be kept in mind when
using bowdens. Firstly, the curves to which the flexible
control is exposed must be very wide and smooth, to avoid
excessive stress on the protective sheath.
• To reduce friction and therefore wear on the cable and
facilitate movement, currently a polyvinyl chloride tube is
placed inside the sheath or, without further ado, while the
metal helix is being built, it is coated with acetal resins. To
also facilitate the movement of the cable, it is advisable to
lubricate the internal cable from time to time.

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EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
3 £RS6
2( • TECHNICAL INSTITUTE

Flexible control systems

aircraft.
• The flexible or bowden control is a mechanical drive system
consisting of a movable cable inside a flexible sheath,
formed by a metal propeller. At the two ends of the sheath,
the metal caps are placed in a suitable manner, which rest or
are attached to the fixed seat, placed as close as possible to
the connecting elements with the cable.
• When the cable is put under tension, the terminals of the
sheath are pushed or forced to tighten against the fixed seat
and, continuing the tensioning action, the sheath behaves as
a curvilinear guide within which the cable moves. ; therefore,

3
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EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
 Flexible aircraft control systems.

Flexible cables , known as 7x7 cables, consist of six strands of seven

wires stretched around one strand of seven wires. This cable is
capable of making superficial bends but cannot pass over very small
pulleys.

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EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
Extra flexible 7x19 cable ,
this type of cable consists of six
strands placed
around a central strand in a
clockwise direction.
Due to its construction, the cable
is easily bent to make turns on the
pulleys. This cable is all
preformed, meaning all wires and
strands are formed before making
the cable.
 • The movements of the control surfaces must of be
synchronized with the
movements of the
Tensiometer
cockpit controls, to accomplish this, the flight controls must
be adjusted, to make a proper adjustment aconveyor
Appropriate should be used and to check the cables a
tension meter is needed.

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 TENSIOMETER

•The tension in a cable is

determined by measuring the amount
of force necessary to make an off-set
in the cable between two hardened
steel blocks called an anvil. A device is
pressed between the cables to form
the off-set.

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 Tensiometer

CABLE 3/16 INCH

DIAMETER

23a

Figure 4-6-5. A cable tensiometer can be used on Installed control systems to

check cable tension.

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 MEASURING THE VOLTAGE IN A CABLE

• Measuring the tension of a cable is a simple process:

• With the trigger down, place the cable between the anvils.

• Close the trigger, the movement of the trigger pushes up the device which
pushes the cable at a right angle to the clamping point under the anvil.

• Read the strength indicated on the dial.

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 MEASURING THE VOLTAGE IN A CABLE

> The tensiometer has a pointer lock or

safety which makes it possible to take
measurements that would otherwise
be impossible, securing this, remove
the cable and observe the reading,
after reading it set the tensiometer to
zero.

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 Measuring the tension in a cable
• Each blood pressure monitor comes with a conversion table which is used to convert the dial reading to pounds, as
shown in the figure below.

STRAIN_____________ Risen Mo. 1 ( risk No. j 3- Yo RISER Na. 3

TEN5ION DIAMETER DIAMETER
DIAMETER
(POUNDS) 1/16 3/32 1/8 5/32 (3/16)—
7/32 1/4
10
14 17 21 IB 26
40 202428 2432
50 253035 2938
60 303542 34 43
(70)- .______________3^ ^4B_________________________________jg __
e5 394554 43$
90 44 50 60 47
1OO * » 65 i1 “

Table 4-6-1. Conversion of tensiometer reading IF pounds

Measuring the tension in a
cable
 PULLEYS AND COMPONENTS OF THE SYSTEM
CABLE TRANSMISSION

• Pulley and belt transmission systems are used to transmit the mechanical
power provided by the motor shaft between two shafts separated from each
other by a certain distance.
• Pulleys are wheels with one or more grooves in the rim, on which the belts
rest.
• Straps are closed ribbons of leather and other materials that are
used to transmit rotational movement between two axes
generally parallel. They can or toothed.

be flat, round, trapezoidal in shape

 ERS.e
TECHNICAL INSTITUTE maintenance inspections
As part of the aircraft maintenance inspection
package, the cables
control must be inspected.
V This is done by rubbing the wires with a flannel to
indicate any broken wires.
V After initial cleaning of the cable, it can be visually
inspected.
V Particular attention should be taken in areas where
cables pass over fairleads, pulleys and quadrants
due to wear on the cables. 46
 • When the cable passes through structure
they use grommet

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 Disposals in cables :
b) fatigue breakage c) repeated bending of pulleys

a)Fallatensil.
about

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EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
 • Inspection by

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

d) Fatigue failure
e) beaten strands

50
EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
 • Fracture failures

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 • Pulley wear

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 • A320 cable system

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 Rudldler Hpcheninal Control Figure 0ni

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 ■ Although wear is one of the factors that
deteriorate the cable, it is also subject to
corrosion.
■ Greater attention should be paid to areas such
as the battery compartment, wheels and sinks
where cables can pass.
■ Cables are often treated with par-alketone to
protect the cable from moisture and corrosion.
■ FAA AC 43.13-1B chapter 7, contains
information on mechanical cables.

5
7
EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz
 REFERENCE MATERIAL
• Michel J. Kroes. Aircraft Basic Science. 7th ed.
Glencoe/McGraw-Hill, 1993
• aircraftsystem maintenance
• avotec
• Aircraft Maintenance Manual for Airbus A319/A320/A321.
• Control Cable Installation and Cleaning – maintenance
Practice, AMM 20-24-11.

– Control cable and pulley check – Inspection/Check, AMM

20-24-12.

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz

 END

57

EIA-EXSAL 11. Control Cables Prepared by TMA Jaime Ortiz