Helical wound cables

Helical cable comprises multi-strand, high tensile steel wire core with additional layers wound over it to form a continuous helical worm. The cable is used in a push-pull system to convert linear motion to rotary (or vice versa) by means of the ‘rack and pinion’ principle.

Gear wheels in the control boxes at either end of the cables engage the main helix wire, which is positioned at a defined pitch. Motion of the cable is then translated through the gear wheel into precise rotary motion.

The cable, which operates in either tension or compression mode, is suitable for high load situations, and when used in conjunction with a flexible conduit is adaptable to a wide range of applications.

Flat wrapped cables

Flat wrapped cables are constructed from a strip of steel wound around a high strength, multi-strand core. They provide particularly high compression strength making them most suitable for controls requiring maximum efficiency with a high compression loading.

They are manufactured in different diameters to cater to differing load requirements, component weight and number of bends that may be necessary.

Piano Wire & Wire Rope

Piano wire is appropriate for light control applications. When used with lined flexible conduit, it provides an extremely light weight control with high efficiency. It is well suited for applications in to compact areas for direct linear movement requirements.

Wire rope is comprised of multiple strands of wound high tensile steel fitted into swaged ends to form a lightweight and adaptable cable. Suitable applications are for tension only controls and for cable and pulley systems along long runs in the aircraft.

Ball Bearing Controls

Ball bearing controls other the advantages of high efficiency and load bearing capabilities with a low amount of backlash. Thus, they are well suited for transmitting tension or compression loads over long distances.

The cable consists of three main components:

• The center core, which is the load-bearing unit that provides axial motion.
• Two ball cages which contain the stainless steel balls on either side of the core. These quide the core and provide for the low friction of the control.
• Two outer races that provide contact surfaces for the steel balls and can move axially.
• The controls are available in different sizes and with different conduit types to suit the temperature, load and other application requirements. They are environmentally sealed and operate safely under a wide range of temperatures.

Rigid Conduits

Teleflex Morse, manufacture both lined and unlined rigid conduits. Lighter in weight than the flexible products, they offer a fully enclosed controlled environment with high damage resistance, particularly the stainless steel range which carries fire resistant qualities verified by British Standard 3G100 Flame test.

Unlined Conduit, available in stainless steel or aluminium, may be easily formed along the length to within the limits of the specified minimum bend radius. It is primarily used in fire zones on engine installations where lined conduit would not be acceptable.

Lined conduits, available in both stainless steel and aluminium, use PTFE as the liner. This provides a conduit with low friction characteristics while maintaining the properties of easy forming and light installations.

Flexible Conduits

Flexible conduits are easily installed in the air frame, and can be designed for more optimal routing. As with rigid conduits, the flexible alternative offers a fully enclosed environment and good damage resistance in both nylon covered and armoured forms.

Nylon covered conduit features a casing comprised of long lay wires wrapped around an acetal lining. It is extremely stable under tension and compression loads and offers efficient controlled movement. Furthermore, the nylon cover provides an oil-resistant casing to ensure the control is waterproof. Nylon covered conduit is ideal for medium load applications in a temperature range of -70C to +85C.

Armored conduit comprises stainless steel wires bound by a stainless steel flat wrapped coil to provide compressive strength. Additional covers may be heat shrunk on to the conduit.

The lining may be PTFE or Beryllium Copper, depending on the temperature requirements of the application. PTFE conduit is used in the range -54C to +250C.

Beryllium Copper is designed for temperatures from -54C to +500C, and is recommended for high load applications and high temperature environments. It has a fire resistance verified by British Standard 3G100 Flame Test.