how to measure aircraft cable tension

Mississauga, Ontario Set-Point feature allowing user to define high and low point specifications which are then shown on the main display as an active, color changing bar graph. Tensitron is a KTC Instruments Company, founded in 1935, which designs, manufactures, sells, and services digital, mechanical and electronic tension measuring instrumentation. Includes carrying case and NIST-traceable calibration certificate, Address Adjustable and nonadjustable stops (whichever the case requires) are used to limit the throw-range or travel movement of the ailerons, elevator, and rudder. Dialing will have some graduation that shows the cable incompatibility with each cable size the instrument can measure. Wear to the anvils and risers can change the calibration readings so tensiometers need to be calibrated regularly to maintain their accuracy. The true tension that the cable is under? Unfortunately, that is not how the cables in our aircraft work. The individual readings are recorded on the calibration card. An additional anti-aging metal garment is provided if the condition requires. Jeff Simon is an A&P, IA, pilot, and aircraft owner. An inexpensive yet accurate method of checking cable tension. The specific riser needed for the appropriate cable size is listed on the calibration card for each tensiometer. Fax: 800-329-3020, West - Corona, CA In HSL type cables each core consists of coated metal sheets with zero potency and a separate lead lead for each landmark. Cable rigging involves the setting of the travel limits and cable tensions of the cables in the aircraft control system. Analog or serial output (optional) After the tab and tab control are in the neutral position, adjust the control cable tension. hb``b``2g`b`| @1 8p6 n&@"-@. ?L0ya4EaJPSyc4#w1? f We are Indias leading aviation organization dedicated towards supporting and helping aviation professionals. Cable Tensiometers come in two basic types, direct-reading and indirect-reading. He has spent the last 22 years promoting owner-assisted aircraft maintenance and recently certified the FlexAlert Multifunction Cockpit Annunciator. Ideal for determining loads on sailboat rigging, guide wires, fences or any application where cable or wires are installed under load. I contacted the engineering team at a large general aviation manufacturer for the answer (they didnt want to go on record with the companys name). Usually there are two sets of stops for each of the three main control surfaces. Then we held the cable in place and removed the tool. Founded in 2018, Aviation A2Z has grown rapidly with 1 Million visitors per year. Typical cable rigging chart. Tensitron instruments are designed to quickly check the tension on aircraft cables from 1/16 in. Rugged units require no oiling & require a minimum of care. 5/32: 140-800 lbs. 2018-2022 Aviation A2Z - Latest Aviation News. Indicate values in Lbs, daN or KG in flexible cables with diameters from 1/16 up to 1/4, CWT cable sizes from 5 to 25 and metric cables from 2.0mm to 4.0mm. High-strength cables: Cables used at 11 kV fall into this category. One protractor that can be used to measureaileron, elevator, or wing flap travel is the universal propeller protractor shown in Figure 2-90. Disagreements can also be defined as the forces of reaction acting on each of these claims. He now shares his expertise through his articles on the Aviation A2Z Website. the limit of their travel when the controls are against their respective stops. Cable tension is determined by measuring the amount of force needed to make an offset in the cable between two hardened steel blocks called anvils. With that mystery solved, I can sleep well at night knowing that my aircrafts bolts are tight, its linkages are within spec, and its cables are under the exact tension that the designers wantedwhatever that might truly be. Thats a 30-percent error in measurement! The ring-to-frame lock prevents the ring from moving when the disk is moved. Typically, at least five readings are taken on each different cable to cover the full measurement range of the cable. After observing the reading, pull the lock out and the pointer returns to zero. Most In Stock Items ordered before Noon CST ship same day. In addition, most control cables are not used anywhere near their load limits. Therefore, the explanations in this chapter are limited to the three general steps listed below: The range of movement of the controls and control surfaces should be checked in both directions from neutral. For the most part, aircraft control cables are closed systems with both ends of the cable fixed, placing the cable under a designed tension. Tensiometers should be calibrated at a minimum of one year or sooner depending on how often the tensiometer is used. Calibration of Cable Tensiometers is usually performed by hanging accurate dead weights from various cables. @`=}c5:jNvx. To compensate for temperature variations, cable rigging charts are used when establishing cable tensions in flight control, landing gear, and other cable-operated systems. %PDF-1.5 % endstream endobj 24 0 obj <> endobj 25 0 obj <> endobj 26 0 obj <>stream Markings on the fixture or template indicate desired control surface travel. Tension meter are designed for a variety of systems including measuring tension of young man cables, wire cord, tower output, overhead lines and more. Well, that might be anyones guess. If jackscrews are used to actuate the trim tab, check to see that they are not extended beyond the specified limits when the tab is in its extreme positions. Calibration certificate included and all calibration values traceable to National Standards. When it has been determined that the aircraft is symmetrical and structural alignment is within specifications, the cable tension and control surface travel can be checked. Leave all boxes unchecked for unit only. Toll Free: 877-477-7823 All of this is done while the cable is installed in the aircraft and under tension. Javascript is disabled in this browser. See the first look in Jetstars new Airbus A321neo cabin, Air India plans mega fleet expansion, Pilots to fly till 65 years of age, Southwest pilots become the 1st mother and daughter duo to fly together. Data Logging Feature: Record tension values to the instruments memory. The dial will have specific graduations that indicate the cable tensions for each of the various cable sizes the instrument can measure. Both types are designed to measure various types of cable, cable sizes and cable tensions. However, when it came time to calibrate my cable tensiometer, the process I witnessed blew my mind. Jeff is also the creator of SocialFlight, the free mobile app and website that maps over 20,000 aviation events, $100 Hamburgers, and educational aviation videos www.SocialFlight.com. Tensiometers are hand-held devices used to measure cable friction. He is very passionate about Writing Aviation Blogs and creating content. Central - Fort Worth, TX endstream endobj startxref For more information and details check out our latest practical and effective video on it: , Link to download Cable Tensiometer Operation & Service Manual: , https://optimanufacturing.com/wp-content/uploads/2018/05/SOP-TN-001_T5_Manual.pdf. Fits cable sizes 3/32, 1/8, 5/32. Each metal spine is covered with a metal sheet held to the ground. 38 0 obj <>/Filter/FlateDecode/ID[<5AF8AFEF096FAFB1A7D6AD993AF57978>]/Index[23 38]/Info 22 0 R/Length 84/Prev 139937/Root 24 0 R/Size 61/Type/XRef/W[1 2 1]>>stream Adjust the control stops to limit the control surface travel to the dimensions given for the aircraft being rigged. Lock the flight deck control, bellcranks, and the control surfaces in the neutral position. As an industry standard, cable tensiometers are calibrated to measure tensions of a free cable. Imagine attaching a cable to the ceiling and suspending a 10-pound weight at the bottom. We are recognized as the leading provider of superior precision tension meters and tension measuring instrumentation used world-wide in manufacturing and test facilities. Until next time, I hope you and your families remain safe and healthy, and I wish you blue skies. (The center spirit level is used to position the frame vertically when measuring propeller blade angle.) This eliminates band separation from the electrostatic field effect. What is the cable Tension with Tensiometer types ? So, why arent aircraft falling out of the sky with up to 30-percent error rates in their cable tensions? #g J5 Bhavya Started Aviation A2Z as a youtube channel and created unique and engaging content for Aviation Professionals. The indirect reading tensiometers require the use of several different removable risers that are used to measure different cable sizes. Where dual controls are installed, they must be synchronized and function satisfactorily when operated from both positions. Parts of an Airplane and their functions. Detailed operating instructions included with each tension gauge. This means that the number we measure accounts for the strain that the measuring tool itself places on the cable (it deflects the cable in order to measure the tension). Options are: 1, 2, 5 and 10 seconds. Aircraft Mechanic School Study Supplement for Future Aviation Maintenance Technicians. Feel free to ask a question or simply leave a comment. Trim tabs and other tabs should be checked in a manner similar to the main control surfaces. They are often used in the aviation industry during cable rigging in aircraft by aircraft manufacturers and for periodic cable maintenance by aircraft maintenance technicians. These tools are used when rigging flight control systems to ensure that the aircraft is properly rigged and the manufacturers specifications have been complied with. Data Averaging: Use this feature to adjust the stability of your displayed, tension readings. If the final alignment and adjustment of a system are correct, it should be possible to withdraw the rigging pins easily. The plunger will move up and the riser will contact the cable at a right angle to the clamping points on the anvils. Rigging fixtures and contour templates are special tools (gauges) designed by the manufacturer to measure control surface travel. Each riser is of a different height which makes it possible to accurately measure tensions of different cable sizes. See your browser's documentation for specific instructions. They have been set to ensure that there isnt too much slack or tension on the pulleys. We attached the tensiometer, then brought the tension up to 15 pounds on the calibration machine. Place your cable tensiometer on the cable and you raise the tension of the cable while measuring it, sometimes by a lot. When the Essco technician calibrated my tensiometer, he did something completely different. This field is for validation purposes and should be left unchanged. Lightweight, portable The rigging of the trim tab systems is performed in a similar manner. Then, place the cable to be tested under the two anvils and close the trigger (move it up). When actually taking a reading of cable tension in an aircraft, it may be difficult to see the dial. Therefore, a pointer lock is built in on the tensiometer. Tension ranges from .5 lb. Included with each tensiometer is a conversion chart, which is used to convert the dial reading to pounds. In the field, mechanics routinely use cable tensiometers to check tensions on aircraft control cables. You clip the tensiometer on the cable and you measure 10 pounds because you still have a 10-pound weight hanging down. Tensiometers have two basic types, direct reading and indirect reading. In order for a control system to function properly, it must be correctly adjusted. When rig pins are not provided, the neutral positions can be established by means of alignment marks, by special templates, or by taking linear measurements. Optional features including: Analog Output and Serial Output, All models typically available from stock, Includes easy to use, cable diameter gage to accurately determine correct cable size, Numerous application specific models available, Durable, lightweight carrying case with protective foam inserts, All instruments factory-calibrated and ready for use. hWmoF+UK/ pGuEg;)qwfmv!1xf#HJ83D2"%HID*&RFL a&KTHG6$s$S>[i"\qXDP sEw0Dh",+$K1Np\"*)dhfsF4CTTF+%hoIzSK}fhO_/aJ>M&h/~-__Q!,G4!`NdO%8vo Next, we did the process in reverse (the way that they calibrate). Direct reading tensiometers will have a dial or digital readout located on the instrument to give the actual tension indication. First-tier Canadian electronics distributor and calibration lab, providing exceptional communications and test and measurement solutions to the service and maintenance entities within the Avionics, Utility, Public Safety, Infrastructure, Wireless, Government and Military markets. Your email address will not be published. The value at this point indicates the tension (rigging load in pounds) to establish on the cable. 2 riser to measure the tension of a 5/32 diameter cable, a reading of 30 is obtained. If the travel in inches is provided, a ruler can be used to measure surface travel in inches. Adjustable LCD refresh rates allowing for stable, digital readouts, Automatic shutoff after several minutes of non-use, Instruments may be operated continuously while connected to power supply. Indirect reading tensiometers contain a larger dial with a scale that reads between 0 and 100. A cloud-based document and ASSET MANAGEMENT PORTAL provides customers with instant access to certificates of calibration, asset information, and reports. In many cases, a graphical chart will be generated from the calibration data. These ruggedly constructed, durable instruments are accurate and reliable. This is a completely different process that results in a completely different tension. Click here to request a FREE quote from one of our experts. There are various types of Polyethylene, polyurethane, polyester elastomer, cellular fluoro polymer fluoroelastomer, Mylicon poly Cables for different purposes. Data storage and statistics They know were not getting an accurate reading, but theyre OK with it because theyve already accounted for it. Copyright 2022 Wicks Aircraft Supply | All Rights Reserved. East - Peachtree City, GA Get your aircraft off the ground and into the air with maximum performance and safety, minimum cost and time. In some cases when measuring aircraft cables, the position of the tensiometer may make it difficult to view the tensiometer dial. Durable construction One set is located at the control surface, either in the snubber cylinders or as structural stops; the other, at the flight deck control. Extremely accurate custom calibration procedure employing up to a 10-point multilinearization procedure. Cable Tensiometers are typically used on aircraft cables that have 7 x 7 or 7 x 19 stranding in the cables and in diameter sizes of between 1/16 through 3/8 of an inch. The position of the tensiometer does not affect the readings so it does not matter whether the calibration cables are placed in a horizontal or vertical position. The calibration card is created for each specific tensiometer. After a system has been adjusted, the full and synchronized movement of the controls should be checked. Definition :- the axial force transmitted by a rope, cable, chain, or similar continuous object in a single orbit. DGCA has begun 2 month special audit of airlines, due to rising tech snags, NASA Boeing 747 damaged in New Zealand Due to Severe Weather, Air France aircraft back to Paris after Technical issues | Exclusive, Exclusive: Aviation Minister inaugurates Spicejets Jabalpur-Kolkata flight, Airlines cant charge extra for a boarding pass at check-in desks in airports: Civil Aviation, DGCA releases Air Traffic Data for June Month, 237% monthly Growth | Exclusive, Jet Airways lenders threaten to go bankrupt, Regarding rental revenue | Exclusive, Exclusive: Pilot Kamal Kumar surprises his family by flying them home | watch what the Pilot did, Indian startup ePlane Company to launch a flying taxi by 2023 | Exclusive. 3 riser column of the chart. There are various tools used for measuring surface travel, including protractors, rigging fixtures, contour templates, and rulers. Selectable units (lb., kg, or daN) SL and HSL Cables: For SL type cables, each spine is covered separately with a lead spine. Adjust the cable tension, maintaining the rudder, elevators, or ailerons in the neutral position. We used Esscos calibration machine to place a cable in a fixed position at a fixed tension (15 pounds), then we attached my tensiometer. Today, the organization has its own website & App, and it is available on multiple platforms. 9325 Progress Parkway Suite B Mentor, OH 44060. Manufactured of rugged anodized aluminum, this gauge is corrosive resistant and will give years of service. Any undue tightness of the pins in the rigging holes indicates incorrect tensioning or misalignment of the system. Southwest - Chandler, AZ The center spirit level is used to position the disk when measuring control surface travel. As the sample chart beneath the illustration shows, different numbered risers are used with different size cables. He did this dozens of times for various tensions and cable sizes until he could properly fill out the new calibration chart for my tensiometer. For more information about COVID-19 please visit: COVID-19 Corona Virus South African Resource Portal, For more information about POPI please visit our Privacy Policy page. Required fields are marked *. Follow the 85 F line upward to where it intersects the curve for 1/8 cable. The tension measured dropped to 10 pounds. The serial number and calibration date are noted on the calibration card for each unit. Various types of protractors are used to determine the travel of flight control surfaces. Protect your instrument in this handy fitted case. Rigging any control system requires that the aircraft manufacturers instructions be followed as outlined in their maintenance manual. The chart makes it easier for the maintenance technicians to determine the correct reading between the calibration points. The tension for this example is 70 pounds. In many instances, the aircraft manufacturer gives the travel of a particular control surface in degrees and inches. Approximately 12 hours of continuous use depending upon backlighting intensity. If you didnt catch on yet to why my mind was blown while witnessing this process, let me explain. Push it in to lock the pointer, then remove the tensiometer from the cable and observe the reading. Copyright 2022 Navair Technolgies Inc. All rights reserved. However, in single spinal cords the loss of spinal cord is greater. Next separate the instruments outer cable contact guides by rotating the engagement lever open and inserting the instrument onto your tensioned cable. One-handed operation Alaska - Wasilla, AK These work as override stops to prevent stretching of cables and damage to the control system during violent maneuvers. Another variable that must be taken into account when adjusting cable tension is the ambient temperature of cable and the aircraft. However, on some aircraft, the specifications may require that the trim tabs be offset a degree or two from streamline when in the neutral position. Features: H-Type Cables: These cables are designed for Hochstaedter and are used for 22 and 33 kV systems. Each riser has an identifying number and is easily inserted into the tensiometer. This feature allows the user to select the duration the instrument takes tension readings over and posting that average to the display. The correct riser must be used for the cable size being measured or incorrect readings will occur and damage to the tensiometer may result. Cable Tensiometers work by measuring the amount of force required to make the cable move between two hardened steel anvils set a specific distance apart. Protractors are tools for measuring angles in degrees. They are commonly used in the aviation industry during aircraft maintenance by aircraft manufacturers and periodically maintained as cable maintenance Task by aircraft maintenance specialists. Following the manufacturers instructions, lower the trigger. Your cable will drop automatically into place and readings will appear on the display once the lever is engaged. Extend a horizontal line from the point of intersection to the right edge of the chart. The Model ACX-1 series of Aircraft Cable Tension Meters are designed to precisely measure static tensions in aircraft cables. However, those situated at the control surface usually perform this function. Indirect reading tensiometers contain larger dials with a scale that reads between 0 and 100. Large, easy to read backlit, color display with adjustable backlighting. This protractor is made up of a frame, disk, ring, and two spirit levels. Each riser has a specific identifying number and is easily inserted onto a pin on the plunger of the tensiometer. The answer is simple: They know that the numbers our gauges are reading arent accurate in an absolute sense. They design cable tensions so our gauges will read 15 pounds when they actually want the cable to be under 10 pounds of tension. A rig pin is a small metallic pin or clip. Aviation A2Z provides the Latest News, Exclusive Blogs, Verified Jobs, and More. 2022 Aircraft Owners and Pilots Association, Approach Aviation introduces expanded alternator coupling tool kit, Aircraft Maintenance: Reaming, lapping, other valve tasks. To measure the tension on a cable, the cable to be tested is placed between the two anvils and the tensiometer handle or trigger is closed. For more information on Cable Tensiometer calibration, contact e2b calibration. Correctly rigged control surfaces move through a prescribed arc (surface-throw) and are synchronized with the movement of the flight deck controls. Tensitron is pleased to announce its 5th generation of digital aircraft cable tension meters, using the latest technology, software, and design improvements providing unsurpassed accuracy and resolution for numerous material sizes and tension ranges. 6375 Dixie Road, Unit 7 Switching accounts in the middle of an order will clear your current cart. Your email address will not be published. [click image to enlarge]To use the chart, determine the size of the cable that is to be adjusted and the ambient air temperature. In the case of a double-stranded wire, each core is closed separately and three cores are fastened with straps. ACX-1 meters are the fastest, easiest way to verify accurate cable tension. When properly maintained, a tensiometer is 98 percent accurate. Color-bar graphic provides quick visual of tension levels A disk-to-ring lock is provided to secure the disk and ring together when the zero on the ring vernier scale and the zero on the disk degree scale align. When checking the range of movement of the control surface, the controls must be operated from the flight deck and not by moving the control surfaces. After determining that the control system functions properly and is correctly rigged, it should be thoroughly inspected to determine that the system is correctly assembled and operates freely over the specified range of movement. The dial reading is converted to pounds of tension as follows. Movement of the trigger pushes up the riser, which pushes the cable at right angles to the two clamping points under the anvils. Please check the boxes for the options that you would like to add. Battery Chargers ,Inverters , Converters, Power Supplies. COVID-19 Corona Virus South African Resource Portal. Bhavya Velani is the Founder of Aviation A2Z. How early before a Flight does the crew come to the Airport? Is Tesla CEO Elon Musk planning to open a new privateairport in Texas. Northeast - Harrisburg, PA Compact design allows access to small spaces Data Statistics: Monitor your process by viewing count, average and standard deviation values of your logged data. The entire cable is covered with a lead shaft through the extraction process to prevent moisture from entering the cable. EHV cables: These cables are usually single-core type because they are easy to carry and install. e2b calibration is an ISO/IEC 17025 ACCREDITED calibration and repair laboratory providing a full scope of NIST TRACEABLE calibration, test, and measurement services for AEROSPACE equipment. 23 0 obj <> endobj Both types are designed to measure different cable types, cable sizes and cable incompatibilities. The calibration machine now read 20 pounds. Customer Service: 800-861-3192 A double 10-part vernier is marked on the ring. To determine the amount of tension on a cable, a tensiometer is used. This page requires Javascript. Services are provided in a climate-controlled, state-of-the-art laboratory with ON-SITE SERVICES, and local pick-up and delivery available on request. In many cases, hydraulic rams or pull test machines can be used to apply the varying forces for the calibration, and load cells can be used to accurately measure the force on the cable. For these requirements the three-core wires will not be able to handle and install as the cable size becomes too large. Power supply operates with input voltages from 100 240V and includes several, interchangeable adapters allowing use with European, Australian, US, English and other plug configurations. As mentioned earlier, when we use a cable tensiometer in the field, we clamp it onto a cable already under tension and read off the resulting number. Calibrations for 7/32 and other cable sizes can be added to the cable selection menu upon request. Either of these may serve as the actual limit stop. The force that the riser contacts the cable is indicated by the pointer on the dial. Canada - Brantford, ON, THE AVIATION SUPERSTORE FOR ALL YOUR AIRCRAFT & PILOT NEEDS | 877-4-SPRUCE. hbbd``b`Z$ HN |@W$$X\ @BPHp .9 `d Up to 10 additional custom calibrations may be programmed into the instrument. The tensiometer must be calibrated on the same type and size of cables on which the instrument is designed to be used. [Figure 2-89]Figure 2-89. Calibrations for other cable sizes are available upon request. to in., CWT cable sizes from 5 to 25, and metric cables from 2.0mm to 4.0mm. A riser or plunger is pressed against the cable to form the offset. First select the cable size from the instruments menu. Rechargeable NiMH batteries with power supply provided. Direct tensiometer readings will have dial or digital readings found in the tool to give a real indication of durability. The other stops do not normally contact each other, but are adjusted to a definite clearance when the control surface is at the full extent of its travel. to 500 lb. Special thanks to the wonderful folks at Essco for opening their doors to my visit during these challenging times. The actual tension (see chart) of the cable is 70 lbs. During the checking of control surface travel, ensure that chains, cables, etc., have not reached. Its products are used in many different industries and companies for a variety of quality control purposes. | Designed by SISConsulting. Or on the other side of a rod, truss member, or similar object with three sides. (adsbygoogle = window.adsbygoogle || []).push({}); Filed Under: Aerodynamics, Aircraft Assembly, and Rigging. Measures wide range of aircraft cable diameters For Use On Cables: 1/16, 3/32, 1/8, 5/32, Sheet Metal Fasteners & Installation Tools, Diamond Plated Integral Pilot Countersinks, Visu/Composi-Lok, Jo-Bolt, Pneumatic Tools, T5 Cable Tensiometer Instruction Manual PDF, Rebuilt & Calibrated Aircraft Cable Tensiometers. A calibration card or graph is supplied with these units that shows a conversion from the dial reading to the pounds of tension for the different cable sizes to be measured. Are you sure you want to switch accounts? Several manufacturers make a variety of tensiometers, each type designed for different kinds of cable, cable sizes, and cable tensions. Using a No. %%EOF Midwest - West Chicago, IL They design it so that everything moves smoothly and safely, then clamp on a tensiometer, see what it says, and put that number into the maintenance manual. The process is simple: Clamp the tensiometer on the cable, take a reading, compare it to the calibration chart with the tool (referencing cable size), and you get the resulting tension.

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