MODULE 6 – MATERIALS AND HARDWARE

SUBMODULE 6.10 - CONTROL CABLES

TYPES OF CABLES; END FITTINGS, TURNBUCKLES AND

COMPENSATION DEVICES ,PULLEYS AND CABLE SYSTEM
COMPONENTS; BOWDEN CABLES; AIRCRAFT FLEXIBLE CONTROL
SYSTEMS.

AIRCRAFT CONTROL CABLES

Aircraft control cables are essential components in the control systems
of many aircraft. They are used to transmit mechanical forces from the
cockpit controls to various parts of the aircraft, such as the ailerons,
elevators, rudders, and landing gear.
1.Stainless Steel Cables:
1. Material: Made from stainless steel, which offers excellent
corrosion resistance and durability.
2. Construction: Often constructed in 7x7 or 7x19 configurations,
where the first number indicates the number of strands and the
second number indicates the number of wires per strand
2. Galvanized Steel Cables:
1. Material: Made from galvanized steel, which has a zinc coating to
protect against corrosion.
2. Construction: Also available in 7x7 or 7x19 configurations

 Flexibility: Aircraft control cables are designed to be flexible, allowing

them to transmit forces around corners and through complex routing
paths.
 Strength: These cables are engineered to withstand significant tensile
forces, ensuring reliable control of the aircraft's systems.
 Durability: Made from high-quality materials to resist wear, corrosion,
and environmental factors
 Inspection and Maintenance
 Regular Inspections: Control cables should be inspected regularly for
signs of wear, corrosion, and broken strands. This is typically done
during annual or 100-hour inspections
 Replacement Criteria: Any cable with broken strands, significant wear,
or corrosion should be replaced. Special attention should be given to
areas around pulleys, guides, and swaged fittings
 Lubrication: Proper lubrication is essential to reduce friction and wear,
especially in areas where the cables pass over pulleys or through guides
 Applications
 Primary Flight Controls: Used to control ailerons, elevators, and rudders,
spoiler
 Secondary Systems: Employed in landing gear, flaps, and other auxiliary
systems.
 Emergency Systems: Integrated into various emergency control systems
for redundancy and safety
 Aircraft control cables are critical for the safe and efficient operation of
an aircraft.
 Proper maintenance and regular inspections are essential to ensure their
reliability and longevity.
 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 very important 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
Aircraft control cables are constructed to ensure flexibility, strength, and
durability.
Common Constructions
1. 7x7 Construction:
1. Description: Consists of six strands of seven wires each, laid
around a center strand of seven wires.
2. Features: Offers a good balance of flexibility and strength.
3. Applications: Commonly used in primary flight control systems
2. 7x19 Construction:
1. Description: Consists of six strands laid around a center strand,
with each strand containing 19 wires.
2. Features: Provides higher flexibility compared to 7x7 construction.
3. Applications: Suitable for applications requiring greater flexibility,
such as control cables that pass over multiple pulleys
3. 3x7 Construction:
1. Description: Consists of three strands of seven wires each.
2. Features: Less flexible than 7x7 and 7x19 constructions.
3. Applications: Used in specific applications where less flexibility is
acceptable
CABLE CONSTRUCTION
 Non-Flexible Cable
 Non-flexible cable may be of the 1 x 7 or 1 x 19 types. The designation
means that the 1 x 7 cable is made up of seven strands, each having only
one wire. The 1 x 19 cable is made up of nineteen strands of one wire
each. Non-flexible cable may be used only for straight runs where the
cable does not pass over any pulleys.
 Flexible Cable
 This cable is of the 7 x 7 type and is made up of seven strands, each of
which has seven wires. Flexible cables are used only for straight runs or
where pulleys are large.
 Extra-Flexible Cable
 Extra-flexible cable is of the 7 x 19 type and is made up of seven strands,
each having nineteen wires each and is used where cables must change
direction over relatively small-diameter pulleys. Extra-flexible cable is
the most commonly used in aircraft flight controls and trim systems.
ADVANTAGES AND DISADVANTAGES OF CABLES
 ADVANTAGES:
1. Compact
2. Light
3. Easy to change direction
 DISADVANTAGES:
1. Requires constant monitoring (Elongation of the cables during use).
2. Highly sensitive to variations in temperature (Adjustments are
sometimes necessary).
3. The tension must be precisely adjusted (Defined by the maintenance
intervals).
4. The tension of the cables applies a load to the aircraft structure, whose
attachments must be reinforced.
SWAGING
 Swaging is a process used to attach end fittings to aircraft control cables,
ensuring a secure and reliable connection. Here are the key details about
aircraft control cable swaging:
 Swaging Process
 Preparation:
  Cable Selection: Choose the appropriate cable and fitting for the
specific application.
 Cutting: Cut the cable to the required length, ensuring a clean and
straight cut
 Fitting Attachment:
 Insertion: Insert the cable end into the fitting. Ensure the cable is
fully seated within the fitting1
 Swaging Tool: Use a swaging tool or machine to compress the
fitting onto the cable. This deformation creates a secure
mechanical bond
 Inspection:
 Go/No-Go Gauge: Check the swaged fitting with a go/no-go gauge
to ensure proper compression
 Visual Inspection: Inspect the fitting for any signs of cracks or
deformation
 Proof-Load Testing:
 Load Application: Apply a proof load to the swaged cable to verify
its strength and integrity. This is typically 50-60% of the cable's
minimum breaking strength
 Paint Marker: Apply a paint marker at the junction of the fitting
and cable. Any cracking of the paint during proof loading indicates
slippage and requires rejection
 Types of Swaged Terminals
 Ball Terminals: Used for attaching cables to quadrants and special
connections where space is limited
 Fork and Eye Ends: Commonly used at cable ends for secure attachment
to control surfaces
 Advantages of Swaging
 Strength: Provides a strong and reliable connection capable of
withstanding significant loads.
 Durability: Resistant to wear and environmental factors, ensuring long-
term performance.
 Precision: Allows for precise control over cable length and tension
 Applications
 Primary Flight Controls: Used in ailerons, elevators, and rudders.
 Secondary Systems: Employed in landing gear, flaps, and other auxiliary
systems
 Swaging is a critical process in the maintenance and assembly of aircraft
control systems, ensuring the safety and reliability of the aircraft.
 Swaging is process of securing the cable to the malleable end fitting by
plastic deformation
 Proof Loading
 Carried out after swaging process to check for the security of the end
fittings.
 British cables carried out to 50% of the minimum breaking load
 American cables to 60 % of the minimum breaking load
 Running splices may be made to join two lengths of cable using two
Nicopress sleeves.
 When two sleeves are used, the splice is approved as having the full
cable strength.
 A safety feature to assist during inspection of Nicopress sleeves is to
apply a band of paint to the junction of the cable and sleeve.
 If the paint band is found broken in service, it is highly likely that the
cable has slipped and further inspection will be required to determine
the cause.
 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. There are a
number of methods to safety a turnbuckle and/or other types of swaged
cable ends that are satisfactory.
 A double wrap safety wire method is preferred.
 Some turnbuckles are manufactured and designed to accommodate
special locking devices.
 Turnbuckles, depending on type, are locked by locknuts and wire.
CABLE TENSIONING
 Control cables are tightened and slackened using the turnbuckles.
Specific cable tension is specified in the aircraft maintenance manual for
every different cable run.
 When cables are rigged excessively tight, it creates a great deal of strain
on the cable system and the aircraft structure because as the day warms
up, the structure will expand or ‘grow’ at a different rate to that of the
control cables.
 Aluminium has a greater coefficient of linear expansion than carbon
steel or stainless steel.
 In extreme cases, the fuselage structure will buckle and deform if cables
are over-tightened during rigging.
 In addition to this, control movement may be more difficult as the cable
tension increases.
 Most aircraft use rig pins to lock the control system in place when
rigging the controls.
 The control surfaces and major quadrants/bellcranks are locked in place
with the rig pins and the cables are tensioned in accordance with the
maintenance manual.
 Tension is adjusted by tightening or loosening the turnbuckles.
 As the turnbuckles have a right- hand thread in one end and a left-hand
thread in the other, turning the turnbuckle in one direction will tighten
the cable run and turning the turnbuckle in the opposite direction will
loosen the cable run.
 With the rig pins in place, adjustments are made at the turnbuckles to
achieve the correct cable tension. Then, a check must be made that each
cable is pulling evenly on quadrants, bell cranks and other intermediate
hardware.
 That is, with the correct cable tension, the rig pins must move freely in
their location holes.
 Tension is checked with a cable tensiometer which must be placed in a
clear area of each section of cable, midway from any quadrants, bell
cranks or surfaces.
 The tensiometer is equipped with a series of risers which correspond to
the cable diameter; 3/32-inch, 1/8-inch 5/32-inch and 3/16-inch are the
most common diameters of control cable, so four risers of
corresponding size are usually adequate.
 The cable is placed between the two anvils and the appropriately-sized
riser, the trigger is closed and the reading on the scale noted.
 A pointer lock locks the reading if necessary. The reading is not the cable
tension – this is an arbitrary reading for the particular riser.
 The tension in pounds is read from a chart which converts the reading
for the riser being used.

 The device incorporates two quadrants mounted on a common fulcrum

and held in place by powerful springs and an indicator scale.
 The aircraft control cables are fitted and locked in the two quadrants. As
the aircraft expands, the cable tension increases, causing the quadrants
to rotate and compress the springs.
 This, basically, maintains a fairly constant cable tension in response to
changes in aircraft structural dimensions.
 A compensator device is required for each set of control cables: usually
ailerons, elevator and rudder, as these are most affected by changes in
structural dimension.
 Cable tension charts are incorporated into all maintenance manuals.

 Quadrants and drums are essential components in aircraft control cable

systems, playing a crucial role in the transmission of control inputs from
the cockpit to various control surfaces.
 Quadrants
 Function: Quadrants are used to change the direction of control cables
and to provide mechanical advantage. They are typically mounted on
pivot points and can rotate to guide the cable along a desired path
 Design: Quadrants are often made from lightweight, durable materials
such as aluminum or composite materials. They feature smooth surfaces
and rounded edges to minimize wear on the control cables
  Applications: Commonly used in throttle, mixture, and propeller control
systems, as well as in flight control systems for ailerons, elevators, and
rudders
 Drums
 Function: Drums are cylindrical components around which control
cables are wound. They are used to convert linear motion into rotational
motion or vice versa
 Design: Drums are typically made from metal and are designed to
provide a smooth, even surface for the cable to wind around. They may
have grooves to guide the cable and prevent slippage
 Applications: Drums are often used in trim systems, where precise
adjustments to control surfaces are required. They can also be found in
winch systems and other applications requiring controlled cable
movement
QUADRANTS AND DRUMS IN AIRCRAFT CONTROL CABLES
 Key Features and Benefits
 Mechanical Advantage: Both quadrants and drums provide mechanical
advantage, allowing for easier and more precise control of aircraft
systems.
 Durability: Made from high-quality materials, these components are
designed to withstand the stresses and strains of aircraft operation.
 Smooth Operation: Properly designed and maintained quadrants and
drums ensure smooth and reliable operation of control cables, reducing
wear and the risk of failure
 Maintenance and Inspection
 Regular Inspections: Both quadrants and drums should be inspected
regularly for signs of wear, corrosion, and proper alignment.
 Lubrication: Ensure that moving parts are properly lubricated to reduce
friction and wear.
 Alignment Checks: Verify that quadrants and drums are correctly
aligned to prevent uneven wear on control cables
  Proper maintenance and regular inspections of quadrants and drums are
essential to ensure the safety and reliability of aircraft control systems.
LOCKCLAD CABLES
 Lockclad is a standard twisted steel wire cable with an aluminium tube
swaged around it. This type of cable has a number of advantages.
 One advantage is that the cable’s coefficient of expansion is nearer that
of the aircraft’s fuselage than the standard steel wire cable.
 As the ambient temperature changes, the cables expand or contract by
almost the same amount as the fuselage structure.
 This combination provides several other advantages:
 It reduces the stretch of the cable over its service life;
 The smooth cylindrical surface provides for closer sealing through
pressure walls;
 It dampens vibrations of the cable;
 Provides greater sensitivity of control.

 Lockclad cables are specialized control cables used in various

applications, including aviation, where high strength, flexibility, and
durability are required.
 Construction
 Inner Cable: Typically made from high-strength stainless steel or
galvanized steel, providing excellent tensile strength and resistance to
corrosion.
 Outer Cladding: The inner cable is covered with a tightly wound helical
wire, often made from stainless steel or other durable materials. This
cladding provides additional strength and protection.
 Protective Coating: The outer cladding is usually coated with a
protective layer, such as nylon or PVC, to enhance durability and reduce
friction.
 High Strength: Lockclad cables are designed to withstand significant
tensile forces, making them suitable for critical control applications.
 Flexibility: The helical wire cladding allows the cable to bend and flex
without compromising its strength, enabling it to navigate complex
routing paths.
 Durability: Resistant to wear, corrosion, and environmental factors,
ensuring long-lasting performance.
 Advantages
 Enhanced Protection: The outer cladding provides additional protection
against abrasion and environmental damage.
 Smooth Operation: The protective coating reduces friction, ensuring
smooth and efficient operation of the control cable.
 Versatility: Suitable for a wide range of applications, from aviation to
marine and industrial settings.
 Lockclad cables are known for their reliability and performance, making
them a popular choice in many critical applications.
 Applications
 Primary Flight Controls: Used in ailerons, elevators, and rudders.
 Secondary Systems: Employed in landing gear, flaps, and other auxiliary
systems
 Ordinary Control Cables
 Ordinary control cables, while still effective, do not have the pre-formed
shape and may be more prone to unraveling and fatigue over time:
 Pre-formed control cables are specifically designed to maintain their
shape and resist unraveling, providing several advantages in aircraft
control systems
 Key Features
 Pre-Formed Shape: The strands of the cable are twisted and set in a
specific shape during manufacturing, ensuring they remain in place and
do not unravel
 Flexibility: Offers enhanced flexibility, making it easier to route through
complex paths within the aircraft
 Fatigue Resistance: Improved resistance to fatigue, which is crucial for
the longevity and reliability of control cables in demanding
environments
  Standard Construction: Made from multiple strands of wire twisted
together, but without the pre-formed setting
 Less Flexibility: May not be as flexible as pre-formed cables, making
them slightly more challenging to route through tight spaces
 Fatigue Resistance: Generally lower fatigue resistance compared to pre-
formed cables
PRE-FORMED CONTROL CABLES
 Comparison
 Durability: Pre-formed cables offer better durability and resistance to
fatigue compared to ordinary cables.
 Flexibility: Pre-formed cables are more flexible, making them easier to
install in complex routing paths.
 Maintenance: Ordinary cables may require more frequent inspections
and maintenance due to their lower fatigue resistance.
Both types of cables have their specific uses and advantages, but pre-formed
control cables are generally preferred in critical applications where reliability
and longevity are paramount
CABLE TERMINATION
 Aircraft control cable terminations are critical for ensuring the secure
attachment of control cables to various components within the aircraft.
 Types of Terminations: Swaged Terminals:
 Description: Swaged terminals are created by compressing a
fitting onto the end of the cable using a swaging tool.
 Types: Common swaged terminals include ball swages, fork ends,
and eye ends.
 Applications: Widely used in primary flight control systems due to
their strength and reliability
  Turnbuckles
 Turnbuckles are devices used to adjust the tension and length of cables,
ropes, and other tensioning systems. They are crucial in ensuring the
proper tension of aircraft control cables.
Components of a Turnbuckle
1. Body:
1. Description: The central component that connects the two
threaded ends. It often features a hexagonal or square shape to
facilitate gripping with a wrench2
2. End Fittings:
1. Description: Typically include eyes, hooks, or threads, which
connect the turnbuckle to the materials being tensioned. Each
turnbuckle has two end fittings, one with right-hand threading and
the other with left-hand threading
3. Threading:
1. Description: Usually made with coarse or fine threads that allow
for easy adjustment. The pitch of the threads affects how much
tension is applied with each turn
  TENSION REGULATORS
 Cable tension regulators are used in some flight control systems because
there is considerable difference in temperature expansion of the
aluminium 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.
CABLE TENSIONING DEVICES
 Importance
 Safety: Ensures that control cables remain properly tensioned,
preventing slack that could impair flight control.
 Reliability: Maintains consistent control inputs, enhancing the reliability
of the aircraft's control systems.
  Adaptability: Automatically adjusts to varying conditions, reducing the
need for manual adjustments
 Proper maintenance and regular inspections of tension regulators are
crucial to ensure their effective operation and the overall safety of the
aircraft.
Operation:
1. Normal Conditions: Under normal conditions, the springs
maintain the tension in the control cables by compensating for
any slack.
2. Temperature and Altitude Changes: As the aircraft experiences
changes in temperature and altitude, the materials in the airframe
expand or contract. The tension regulator adjusts the cable
tension accordingly to maintain consistent control
3. Structural Flexing: During take-off, landing, or other maneuvers,
the airframe may flex. The tension regulator compensates for
these changes, ensuring the control cables remain properly
tensioned

SPLICING PROCESS
 Splicing aircraft control cables is a critical process that ensures the
integrity and reliability of the control systems. Types of Splices
1. Nicopress Splice:
1. Description: Uses oval-shaped sleeves that are crimped onto the
cable using a special tool.
2. Materials: Typically made from copper or aluminum.
3. Applications: Commonly used for splicing control cables in various
aircraft systems
2. Swaged Splice:
1. Description: Involves compressing a fitting onto the cable using a
swaging tool.
2. Materials: Made from stainless steel or other durable metals.
 3. Applications: Used in primary flight control systems due to their
strength and reliability
3. Preparation:
1. Cutting: Cut the cable to the required length, ensuring a clean and
straight cut.
2. Cleaning: Clean the ends of the cable to remove any dirt or debris
4. Fitting Attachment:
1. Insertion: Insert the cable end into the splice sleeve or fitting.
2. Crimping/Swaging: Use the appropriate tool to crimp or swage
the fitting onto the cable. Ensure the fitting is properly
compressed and secure
5. Inspection:
1. Go/No-Go Gauge: Check the spliced fitting with a go/no-go gauge
to ensure proper compression.
2. Visual Inspection: Inspect the splice for any signs of cracks or
deformation
6. Proof-Load Testing:
1. Load Application: Apply a proof load to the spliced cable to verify
its strength and integrity. This is typically 50-60% of the cable's
minimum breaking strength
2. Paint Marker: Apply a paint marker at the junction of the fitting
and cable. Any cracking of the paint during proof loading indicates
slippage and requires rejection

 Importance of Proper Splicing

 Safety: Ensures the secure attachment of control cables, preventing
failures.
 Reliability: Provides consistent and reliable control inputs.
 Durability: Extends the lifespan of control cables and reduces
maintenance needs
 Proper splicing of aircraft control cables is essential for maintaining the
safety and efficiency of the aircraft's control systems. Regular
inspections and adherence to splicing procedures are crucial to ensure
the integrity of the splices.
 Pulleys
 Pulleys are essential components in aircraft control systems, guiding
control cables and changing the direction of force.
 Key Features
 Grooved Wheels: Pulleys have grooved wheels to guide the cable and
prevent it from slipping off.
 Materials: Typically made from durable materials such as metal or high-
strength plastic to withstand the forces applied
 . Bearings: Equipped with bearings to reduce friction and ensure smooth
operation
 Applications
 Control Systems: Used to guide control cables in aircraft, ensuring
smooth and precise movement of control surfaces.
  Pulley Wear Patterns and Their Causes
 Understanding the wear patterns on aircraft control cable pulleys can
help diagnose underlying issues.
1. Pulley Misalignment
 Wear Pattern: Uneven wear on one side of the pulley.
 Cause: Misalignment causes the cable to rub against one side of the
pulley more than the other, leading to uneven wear
  Effect: Reduced power transmission efficiency, increased energy
consumption, and decreased equipment lifespan
2. Excessive Cable Tension
 Wear Pattern: Accelerated wear across the entire pulley surface.
 Cause: Excessive tension increases the pressure between the cable and
the pulley, causing faster wear
 Effect: Difficulties in operating control surfaces, premature wear, and
potential cable breakage
Cable Misalignment
 Wear Pattern: Irregular wear patterns, often with more wear on one
side or at specific points.
 Cause: Misalignment causes the cable to not sit properly in the pulley
groove, leading to uneven wear.
 Effect: Increased friction, reduced cable life, and potential for cable
slippage.
4. Pulley Too Large for the Cable
 Wear Pattern: Flattening of the cable and uneven wear in the pulley
groove.
 Cause: A pulley that is too large for the cable does not support the cable
properly, causing it to flatten and wear unevenly.
 Effect: Accelerated wear on the cable, reduced service life, and potential
for cable failure
5. Frozen Bearing
 Wear Pattern: Localized wear or grooving in the pulley.
 Cause: A frozen bearing prevents the pulley from rotating, causing the
cable to slide over a stationary surface, leading to localized wear.
 Effect: Increased friction, potential cable damage, and reduced efficiency
of the control system.
 Inspection and Maintenance Tips
 Regular Inspections: Conduct regular inspections to identify wear
patterns early and take corrective actions.
 Alignment Checks: Ensure pulleys and cables are correctly aligned to
prevent uneven wear.
 Tension Adjustments: Maintain proper cable tension to avoid excessive
wear.
 Bearing Maintenance: Regularly check and lubricate bearings to ensure
they are functioning properly.
 Proper maintenance and regular inspections are crucial to ensure the
safety and reliability of aircraft control systems
 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 indication of other problems in the cable system.
 If a pulley shows signs of wear on one side the cable is misaligned.
 Cable guards are essential for protecting cables and hoses from damage
and preventing accidents such as trips, slips, and falls. Here are some key
details about cable guards:
 Key Features
 Material: Made from durable materials such as polyethylene, rubber, or
metal to withstand various environmental conditions
 Benefits
  Safety: Reduces the risk of tripping and electrical hazards by keeping
cables organized and protected.
 Durability: Extends the lifespan of cables by shielding them from wear
and tear.
Cable guards are a vital safety tool in many environments, providing protection
for both cables and people
 Fairleads are essential components used to guide ropes, cables, or lines
in various applications, ensuring they follow a smooth and low-friction
path. Here are some key details about fairleads:.
 Key Features
 Low Friction: Designed to reduce friction and chafing, ensuring smooth
operation of lines and cables.
 Durability: Made from robust materials such as stainless steel, bronze,
or high-strength plastics to withstand harsh environments
 Importance of Fairleads
 Safety: Prevents lines from rubbing against sharp edges or surfaces,
reducing the risk of damage and failure.
 Efficiency: Ensures smooth and efficient operation of lines and cables,
minimizing wear and tear.
 Versatility: Suitable for a wide range of applications, from marine and
nautical to industrial and construction settings
Aircraft control cable pressure seals are crucial components used to maintain
the integrity of a pressurized aircraft cabin while allowing control cables to
pass through the pressure vessel.
Function
• Sealing: Pressure seals prevent the leakage of pressurization air from the
cabin, ensuring that the aircraft maintains the required pressure levels.
• Flexibility: They allow control cables to move freely while maintaining a
tight seal around the cable
• .Construction
• Materials: Typically made from durable, flexible materials such as
rubber or elastomers that can withstand the pressure differential
between the cabin and the outside environment
• .Grease-Filled: Many pressure seals are filled with grease to reduce
friction and allow smooth movement of the control cables
• Applications
• Control Systems: Used at each location where a control cable penetrates
the structure of a pressure vessel, such as in the cockpit controls for
ailerons, elevators, and rudders1
• Maintenance
• Regular Inspections: Pressure seals should be inspected regularly for
signs of wear, cracking, or degradation.
• Replacement: Any damaged or worn seals should be replaced promptly
to ensure the integrity of the pressurized cabin1
• Proper maintenance and regular inspections of pressure seals are
essential to ensure the safety and efficiency of the aircraft's control
systems.
PUSH RODS (CONTROL RODS)
 Notice that it consists of a tube with threaded rod ends. An adjustable
antifriction rod end, or rod end clevis, attaches at each end of the tube.
 The rod end, or clevis, permits attachment of the tube to flight control
system parts.
 The check nut, when tightened, prevents the rod end or clevis from
loosening.
 They may have adjustments at one or both ends.
 The rods should be perfectly straight, unless designed to be otherwise.
 When installed as part of a control system, the assembly should be
checked for correct alignment and free movement.
TRAVEL ADJUSTMENT
 Control surfaces should move a certain distance in either direction from
the neutral position.
 These movements must be synchronized with the movement of the
flight deck controls.
  The flight control system must be adjusted (rigged) to obtain these
requirements.
 The tools for measuring surface travel primarily include protractors,
rigging fixtures, contour templates, and rulers.
 These tools are used when rigging flight control systems to assure that
the desired travel has been obtained.
RIGGING
 Generally speaking, the rigging consists of the following:
1. Positioning the flight control system in neutral and temporarily locking it
there with rig pins or blocks;
2. Adjusting system cable tension and maintaining rudder, elevator, and
ailerons in the neutral position; and
3. Adjusting the control stops to the aircraft manufacturer's specifications.

FLEXIBLE SHAFT CONTROLS (BOWDEN CABLES)

 AIRCRAFT FLEXIBLE CONTROL SYSTEMS
The following two systems are widely used:
1. Tele cable controls, made up of a metal core that slides inside a metal
sheath,
2. The tele force and tele flex controls made up of a metal core that slides
on a row of balls.
 ADVANTAGES
 They have the following advantages:
 Very low weight,
 Easy routing. They are used in non-straight sections.
 Nevertheless, the bend radii are to be complied with,
 Very small overall dimension,
  They are used to operate in traction and compression.
 USE
Flexible transmissions installed on an aircraft work along the same principle
as cable-operated bicycle brakes.
However, on an aircraft, they operate both in traction and in They are
installed for remote manoeuvring of components with little resistance:
 Fuel valves,
 Combustion gas valve
 Cooling hood flap
 Landing gear snap lock
 Emergency System
 Parachute Control
Throttle control
  A Bowden cable is a type of flexible cable used to transmit mechanical
force or energy by the movement of an inner cable relative to a hollow
outer cable housing.
 Components
1. Inner Cable:
1. Material: Typically made of steel or other high-strength materials.
2. Design: Can be solid or stranded and is often coated with a
lubricant to reduce friction and wear
2. Outer Housing:
1. Material: Usually made of flexible materials such as nylon, PVC, or
Teflon.
2. Reinforcement: May include braided or spiral wires for added
strength and durability
3. End Fittings:
1. Types: Common fittings include clevises, eyelets, studs, and ball
joints.
2. Function: Connect the Bowden cable to the device it is controlling
Ferrules:
 1. Function: Small components used to secure the end fittings to the
Bowden cable
 Working Principle
 Force Transmission: The inner cable moves within the outer housing,
transmitting force or motion from one end to the other.
 Push/Pull Mechanism: The cable can transmit both pulling and pushing
forces, depending on the application
 Advantages
 Flexibility: Can be routed through complex paths and around obstacles.
 Durability: Resistant to wear and environmental factors.
 Versatility: Suitable for a wide range of applications
 A Bowden cable is a type of flexible cable used to transmit mechanical
force or energy.
 An inner steel or stainless-steel cable is free to slide inside an outer
cable housing.
 The housing may be constructed of various materials but is traditionally
a heavy gauge helical steel wire.
 The inner cable moves linearly to transmit force while the outer housing
is typically fixed at both ends.
 Light single engine aircraft often use a Bowden cable to open and close
the throttle.
 Carburettor mixture controls can also be operated this way throttle.
Carburettor mixture controls can also be operated this way.
 It is made up of a flexible cable (usually twisted steel), sliding in a flexible
sheath.
 Both ends of the cable are equipped with swaged or screwed end-
fittings, in order to connect one mechanical component to another.
 The sheath, made up of a closed-coil spring, is enclosed in a cotton or
plastic sheath. Both ends of the sheath are blocked by drilled stops to
allow the cable through.
 It is used in lightweight aircraft, mainly for throttle controls, hood
opening, or for the manual opening of the main landing gear doors (e.g.
Mirage F1).
 ADVANTAGES AND DISADVANTAGES
 The main advantages are:
1. Lightness,
2. Good value,
3. Easy to use.

 The main disadvantages are:

1. Requires lubrication,
2. Dust ingress through the ends,
3. Subject to rupture or blocking (frayed cable, broken sheath),
4. Extensible.
 Teleflex cables, also known as control cables, are widely used in various
applications, including marine, automotive, and industrial settings.
 Key Features
 Smooth Operation: Teleflex cables are designed to provide smooth and
efficient control with minimal lost motion, even in long and complex
cable routings
 Durable Construction: Made with high-density polyethylene (HDPE)
outer jackets that are abrasion-resistant and provide high resistance to
water penetration
 Lubrication: These cables are typically lubricated for life, ensuring long-
lasting performance without the need for additional maintenance
 Advantage
 High Efficiency: Provides unparalleled smoothness and efficiency with
hardly any lost motion
 Versatility: Suitable for a wide range of applications, from marine to
industrial settings
 Durability: Resistant to UV, saltwater, chemicals, and abrasion, ensuring
long-lasting performance
 Teleflex cables are known for their reliability and performance, making
them a popular choice in various industries.
FLEXIBLE CONTROL SYSTEMS
BOWDEN AND TELEFLEX CONTROL CABLES
 Bowden cables are usually designed to apply a pulling action only,
normally the return action is supplied by a spring.
 If a pull/push action is required then control rods can be used. however
these are heavy and space consuming.
 Bowden and Teleflex are two cable systems.
  PRECAUTIONS
 When a control (tele force or tele flex) is spread out on a table or during
installation on the aircraft, it is imperative:
 to keep the angle of the original preformed controls (angle that is
complied with in the packaging).
 not to subject the control to distortions with a bend radius below the
authorised minimum bend radius.
 When a control is to be examined, all precautions must be taken when
removing and packaging the flexible control.
 PRECAUTIONS
 When a long-length control is to be packed for transport or storage, it
must be coiled in a figure of "8", to keep to the minimum bend radius.
Only this form of packaging prevents damage to the internal rails.
 The control must always be handled with care (end-fitting protection
installed). Avoid any torsion or twisting stress.
 Keep the rails oriented in the radius of curvature plane.
 The sheath must never have a fold at the end-fitting inlet.