Aircraft Control Cables and Tools PDF

GROUP 2 COMPANY Aircraft Control Cables and Cable Assemblies By: Phil Jeroz Aguilar John Ronie Ilagan Prince Veluz Aircraft Control Cables are essential for transferring mechanical control movements from the cockpit to various components like ailerons, elevators, rudders, and other...

GROUP 2 COMPANY Aircraft Control Cables and Cable Assemblies By: Phil Jeroz Aguilar John Ronie Ilagan Prince Veluz Aircraft Control Cables are essential for transferring mechanical control movements from the cockpit to various components like ailerons, elevators, rudders, and other critical flight systems. Cable Assemblies are pre-configured sets of control cables designed to meet specific control requirements, assembled with necessary end fittings and connections.  Aircraft Control Cables FUNCTION MATERIALS Data analytics Control cables transfer pilot inputs Made primarily from stainless steel 7x7 Cable: Consists of 7 strands of 7 wires, commonly used for less critical systems from the cockpit to flight control or galvanized carbon steel for where flexibility is essential. surfaces and other systems. strength, flexibility, and corrosion 7x19 Cable: Comprises 7 strands of 19 wires, resistance. offering higher strength and flexibility, often used in primary control systems.  Types of Aircraft Control Cables Primary Control Cables Used to connect the pilot controls to primary flight surfaces (ailerons, elevators, rudders) that directly affect the aircraft’s attitude and direction.  Types of Aircraft Control Cables Secondary Control Cables Operate secondary flight control surfaces like flaps, spoilers, and trim systems that influence lift and drag but not the aircraft's primary control. Cable Assemblies What is a Cable Assembly? A collection of cables, connectors, and terminations pre-configured to meet specific control system requirements. Assembly Components 01 02 03 04 Turnbuckles: To Swaged terminals: Cable guards Pulley systems: adjust tension in Permanent fittings and fairleads: Change the control cables. attached to the Protect cables direction of ends of control from abrasion control cable cables, forming and wear. forces and help strong connections. in transferring motion efficiently. Safety Considerations Regular Ensuring Preventing inspection of proper excessive slack, wear and tension and which may lead tear. alignment. to control issues.  GROUP 2 COMPANY Aircraft Tools /Equipment (Tools, Fabrication, and Repair Equipment) By: Phil Jeroz Aguilar John Ronie Ilagan Prince Veluz Tools and Equipment used in the fabrication, installation, and repair of these cables are crucial for ensuring safety, reliability, and performance.  Aircraft Tools and Equipment for Cable Handling Installation Tools SWAGING TOOLS CABLE CUTTERS TENSIOMETERS For attaching terminals to Precision tools to cut steel To measure the tension of cables by compressing them cables without fraying. installed control cables and securely. ensure correct tensioning.  Aircraft Tools and Equipment for Cable Handling Repair Tools NICO-PRESS TOOLS CABLE TESTERS PULL TEST MACHINES For crimping sleeves onto Used to check the integrity of the Ensure that the swaged ends cables, used for emergency control cables. of the cable can withstand repairs. the forces they will encounter.  Aircraft Tools and Equipment for Cable Handling Maintenance Tools GREASE GUNS AND INSPECTION MIRRORS LUBRICATION TOOLS AND BORESCOPES For preventing wear and friction For examining hard-to-reach on cable systems. areas and ensuring there are no frays or wear.  Fabrication and Repair Equipment Fabrication Equipment CABLE FABRICATION END FITTING PRECISION GRINDERS MACHINES MACHINES AND DEBURRING TOOLS For cutting, swaging, and Used to apply the terminals at Ensure that cables and assembling control cables. the ends of control cables. fittings are smooth and free of sharp edges that may cause wear.  Fabrication and Repair Equipment Repair and Maintenance PORTABLE SWAGING HYDRAULIC CABLE SPLICING UNITS PRESSES TOOLS Allow on-site repairs or Used to swage terminals onto To join cables together in modifications. cables with precise control over case of damage or wear. pressure and fitting quality.  GROUP 2 COMPANY ALL TOOLS AND EQUIPMENTS Aircraft maintenance, repair, and operations require a wide variety of specialized tools and equipment. These tools ensure safety, precision, and efficiency in keeping aircraft airworthy. By: Phil Jeroz Aguilar John Ronie Ilagan Prince Veluz  ALL TOOLS AND EQUIPMENTS Basic Hand Tools SCREWDRIVERS: FLATHEAD, PHILLIPS, TORX, WRENCHES: OPEN-END, BOX-END, AND SPECIALIZED SCREWDRIVERS FOR ADJUSTABLE, AND TORQUE WRENCHES AIRCRAFT FASTENERS Tightening or loosening screws on Loosening or tightening nuts and panels, interiors, and electronics. bolts, with torque wrenches providing precise force application.  ALLTOOLS AND EQUIPMENTS Basic Hand Tools PLIERS: NEEDLE NOSE, LOCKING PLIERS, SOCKETS AND RATCHETS: AVAILABLE IN DIAGONAL CUTTERS, AND SAFETY WIRE VARIOUS METRIC AND IMPERIAL SIZES PLIERS Gripping, cutting, bending, and Turning fasteners in tight or difficult- applying safety wire to secure to-reach places. fasteners.  ALL TOOLS AND EQUIPMENTS Basic Hand Tools HEX KEYS (ALLEN WRENCHES): FOR FASTENERS WITH HEXAGONAL RECESSES Used commonly in avionics and interior fittings.  ALL TOOLS AND EQUIPMENTS Measuring and Inspection Tools CALIPERS AND MICROMETERS: DIGITAL, FEELER GAUGES: THIN METAL STRIPS OF DIAL, OR VERNIER TYPES VARYING THICKNESS Measuring thickness, depth, and Measuring gaps between parts, such diameter of components with high as in engine components. precision.  ALL TOOLS AND EQUIPMENTS Measuring and Inspection Tools BORESCOPES: VISUAL INSPECTION TOOL DIAL INDICATORS: USED TO MEASURE WITH A CAMERA SMALL DISTANCES OR ALIGNMENTS Inspecting internal components of Ensuring precise alignment and engines, turbines, and other areas movement in rotating parts. without disassembly.  ALL TOOLS AND EQUIPMENTS Measuring and Inspection Tools ULTRASONIC TESTERS: FOR NON- DIAL INDICATORS: USED TO MEASURE DESTRUCTIVE TESTING OF MATERIALS SMALL DISTANCES OR ALIGNMENTS Detecting internal cracks or defects Detecting surface or near-surface in materials like metals or defects in metal components. composites.  ALL TOOLS AND EQUIPMENTS Power Tools DRILLS (ELECTRIC AND PNEUMATIC): FOR GRINDERS AND SANDERS: FOR SURFACE DRILLING HOLES IN AIRCRAFT STRUCTURES PREPARATION OR SHAPING METAL PARTS Creating fastener holes in materials Smoothing surfaces, removing like aluminum, titanium, and corrosion, or shaping components. composites.  ALL TOOLS AND EQUIPMENTS Power Tools RIVETING GUNS AND BUCKING BARS: IMPACT WRENCHES: POWERFUL TORQUE PNEUMATIC TOOLS USED FOR RIVET TOOLS INSTALLATION Fastening skin panels or structural Rapidly loosening or tightening large components using rivets. bolts, such as those used in landing gear.  ALL TOOLS AND EQUIPMENTS Power Tools AIR COMPRESSORS: POWER PNEUMATIC TOOLS LIKE DRILLS AND RIVET GUNS Providing compressed air to operate a wide range of air tools.  ALL TOOLS AND EQUIPMENTS Aircraft-Specific Tools SAFETY WIRE PLIERS: FOR TWISTING SAFETY PITOT-STATIC TESTERS: FOR TESTING THE WIRE TO LOCK FASTENERS PITOT-STATIC SYSTEM Preventing loosening of critical Ensuring accurate airspeed, altitude, fasteners due to vibration. and rate of climb/descent readings.  ALL TOOLS AND EQUIPMENTS Aircraft-Specific Tools PROPELLER PROTRACTORS: TOOLS FOR BRAKE BLEEDING KITS: FOR REMOVING AIR SETTING AND MEASURING PROPELLER FROM HYDRAULIC SYSTEMS BLADE ANGLES Ensuring proper propeller pitch for Ensuring air-free hydraulic fluid in efficient aircraft performance. brake systems.  ALL TOOLS AND EQUIPMENTS Ground Support Equipment (GSE) TOW BARS AND TUGS: EQUIPMENT USED TO GROUND POWER UNITS (GPUS): PROVIDE MOVE THE AIRCRAFT ON THE GROUND ELECTRICAL POWER TO THE AIRCRAFT WHILE ON THE GROUND Towing or pushing the aircraft in and Supplying electricity to avionics and out of the hangar or ramp areas. other systems without the need for engine power.  ALL TOOLS AND EQUIPMENTS Ground Support Equipment (GSE) HYDRAULIC POWER UNITS (HPUS): SUPPLY AIRCRAFT JACKS: USED TO LIFT THE HYDRAULIC PRESSURE TO AIRCRAFT AIRCRAFT FOR INSPECTIONS AND REPAIRS SYSTEMS Testing and operating hydraulic Elevating the aircraft for tasks like tire systems, such as landing gear or changes, gear inspections, or flight controls, without engine structural repairs. operation.  ALL TOOLS AND EQUIPMENTS Ground Support Equipment (GSE) OXYGEN AND NITROGEN CARTS: FOR DE-ICING EQUIPMENT: SPECIALIZED SERVICING OXYGEN AND NITROGEN EQUIPMENT TO REMOVE ICE FROM AIRCRAFT SYSTEMS SURFACES Filling oxygen tanks or nitrogen- Preventing ice buildup on wings and charging landing gear struts and tires. control surfaces before takeoff.  ALL TOOLS AND EQUIPMENTS Avionics Tools MULTIMETERS: MEASURES ELECTRICAL OSCILLOSCOPES: VISUALIZE ELECTRICAL VALUES LIKE VOLTAGE, CURRENT, AND SIGNALS FOR DIAGNOSTICS RESISTANCE Diagnosing and troubleshooting Troubleshooting complex electronic electrical and avionics systems. systems and signal integrity in avionics.  ALL TOOLS AND EQUIPMENTS Avionics Tools CRIMPING TOOLS: USED FOR CREATING CABLE TESTERS: USED TO CHECK THE SECURE ELECTRICAL CONNECTIONS CONTINUITY AND PERFORMANCE OF ELECTRICAL CABLES Attaching connectors to wires in Ensuring proper connectivity and avionics and electrical systems. signal flow in wiring systems.  ALL TOOLS AND EQUIPMENTS Safety and Protective Equipment FIRE EXTINGUISHERS: REQUIRED FOR FIRE PERSONAL PROTECTIVE EQUIPMENT (PPE): SAFETY IN HANGARS AND AROUND INCLUDES GLOVES, GOGGLES, HEARING AIRCRAFT PROTECTION, AND STEEL-TOED BOOTS Suppressing potential fires in Protecting workers from mechanical maintenance areas. hazards, noise, and chemical exposure.  ALL TOOLS AND EQUIPMENTS Safety and Protective Equipment FALL PROTECTION GEAR: HARNESSES AND LIFELINES USED WHEN WORKING ON HIGH SURFACES Preventing falls during maintenance on wings, fuselage, or tail sections.  ALL TOOLS AND EQUIPMENTS Lifting and Hoisting Equipment ENGINE HOISTS: USED TO LIFT AND MOVE WING AND TAIL STANDS: PROVIDE ACCESS ENGINES TO ELEVATED PARTS OF THE AIRCRAFT Installing or removing aircraft engines Supporting technicians working on during overhauls or repairs. the aircraft’s wings or tail sections.  ALL TOOLS AND EQUIPMENTS Material Handling Equipment TOOL CARTS AND CHESTS: MOBILE STORAGE FORKLIFTS AND PALLET JACKS: USED TO UNITS FOR TOOLS MOVE LARGE AND HEAVY PARTS OR EQUIPMENT Organizing and transporting tools Handling components like engine during maintenance tasks. parts, aircraft sections, or heavy GSE. C O Importance of Control Cables and Assemblies: N 01 Control cables are critical to the safe operation of aircraft, ensuring that all control surfaces C respond as expected to pilot inputs. L Tools and Equipment: Proper tools for installation, 02 maintenance, and repair are essential for U ensuring that cables perform reliably throughout their service life. S Safety and Inspection: Regular maintenance I 03 and inspections, along with the right equipment, play a significant role in preventing O mechanical failures and ensuring flight safety. N THANKYOU!!