With more than 50 years of experience in custom wire rope and cable assemblies, Lexco Cable has been a trusted partner for aerospace, military, and industrial applications. As the aerospace industry evolves, the demand for precision-engineered components that meet stringent safety and performance standards has never been greater. Follow along as Lexco Cable shares their perspective on the critical role of wire rope and cable assemblies in modern aerospace engineering, highlighting their applications, safety features, and innovations shaping the future of the industry.
[All photos courtesy of Lexco Cable]
Wire rope and cable assemblies are vital for aerospace engineering. From commercial and military applications to NASA, who uses cables and ropes on the ISS, these components are indispensable. In fact, wire rope is used so frequently in the aerospace industry that it is often known as “aircraft cable.”
Like many components in aerospace, the simplicity of wire rope and cable assemblies often belies their critical function. Wire rope and cable assemblies are versatile, strong, and reliable. These features make them crucial to the success of a variety of aerospace engineering projects. Aerospace construction, maintenance, and daily operation all rely on wire rope and cable assemblies.
In this article, we’ll discuss the features that make these components so useful and illustrate some common uses for wire rope and cable assemblies in modern aerospace engineering.
Features of Wire Rope and Cable Assemblies
The aerospace industry is a diverse sector that covers everything pertaining to aircraft and spacecraft. It is generally segmented into aviation, which encompasses all kinds of planes, jets, and military aircraft, and space, which includes satellites, rockets, shuttles, and emerging technologies for private space tourism. Aerospace engineering includes the development and maintenance of crafts, as well as the broader infrastructure to support them.
Due to these complex operations, aerospace technology requires the highest level of precision, durability, and load-bearing capacity. Additionally, the Federal Aviation Administration enforces important safety regulations for cables used in aircraft. Industrial wire rope and cable assemblies are uniquely positioned to fulfill these needs.
Several features stand out that make these components essential for aerospace engineering:
Extrusion Coating
To make wire rope, manufacturers twist multiple strands of metal wire into a single rope or cable. The specific metal or alloy, rope thickness, tensile strength, and other properties can be customized for different uses. For aircraft cable, the wire rope is then coated via extrusion with a layer of nylon, polyvinyl chloride (PVC), or high-density polyethylene (HDPE). This process is also known as “jacketing.”
This extrusion coating protects the cable inside from corrosion, abrasion, and other wear-and-tear. It enables the wire rope to withstand the harsh, demanding environments often encountered in the aerospace industry – including the exposed vacuum of space.
Whether tethering aircraft equipment or hauling cargo, extrusion coating reduces friction and thereby increases the lifespan of the wire rope inside. The coating’s ergonomic surface also improves lubrication of cable assemblies.
Safety
Wire rope and cable assemblies also provide an additional level of safety. Jacketed wire ropes are available in a variety of bright colors, which increases visibility during inclement weather or other low-visibility conditions. Fluorescent red, neon yellow, or dayglo orange coatings help workers stay alert.
In some operations, a specific color may be used to convey messages about the wire rope’s function. This color-coded messaging can be incorporated into a project-wide safety system to reduce errors and accidents.
As previously mentioned, extrusion coated aircraft cable is engineered to reduce friction. This provides another layer of safety. The cable assemblies for aerospace are smoother, which improves the movement of wire ropes and helps prevent snagging or other impediments that could lead to safety hazards.
Customizability
Most aerospace cable assemblies are designed in 7×7 (seven strands of seven wires) or 7×19 (seven strands of 19 wires) configurations. Each assembly varies in flexibility in order to fulfill different functions. For example, a 7×19 cable assembly is more flexible, which makes it an excellent component for hoisting, winching, or other applications that require tighter or more frequent turns.
“Sometimes there’s crossovers between aerospace specifications and military specifications. For example, Boeing BACT14B cross references to NAS494,” says David Karbin, the Vice President of Lexco. This type of overlap is critical for ensuring that components, such as wire ropes, meet the stringent durability, load-bearing, and safety requirements needed in both aerospace and military environments. By utilizing dual standards, manufacturers can create versatile solutions that are trusted across industries, enhancing the reliability of systems like aircraft control mechanisms and military rescue operations.
Wire ropes for the aerospace industry can also be manufactured from galvanized steel or corrosion-resistant steel. They can be extrusion coated, to deliver the benefits previously mentioned, or left bare. Other cable assemblies are engineered to be non-rotating. A non-rotating cable, often used by the military, is ideal for rescue operations and flight controls.
“Utilizing military specifications will continue to be popular for aerospace applications. For example, aircraft cable per MIL-DTL-83420”, explains Karbin. These specifications offer a proven framework for quality and performance that aerospace engineers can rely on. Whether it’s for hoisting cargo, stabilizing critical equipment, or controlling flight systems, wire rope built to military specs delivers the necessary strength and reliability to perform in extreme conditions.
Common Aerospace Uses
The aerospace industry faces unique challenges. Wire rope and cable assemblies offer a solution thanks to their solid construction and reliable performance. These components are used in a myriad of diverse applications, from small-scale private operations to government projects in aviation, space, and the military. Some common applications include:
Construction and Maintenance
Aerospace wire rope and cable assemblies are manufactured with advanced materials and techniques. This makes them well suited to withstand the high demands of aerospace construction and maintenance. From winching parts by crane to securing wide-loads during transport, and other functions, these components are vital to aircraft and spacecraft engineering.
Aircraft Control Systems
Control systems include hydraulic actuators, brakes, landing gears, and various steering mechanisms for stability and maneuverability. Wire rope and cable assemblies support these systems, and more, thanks to their friction-resistant features and customizability.
Spacecraft and Satellite Deployment
Astronauts and engineers working on spacecraft use wire rope and cable assemblies to handle many jobs. This includes operating robotic arms and specialized assemblies for deploying satellites, adjusting solar panels and antenna, and other functions in the harsh, exposed environment of space.
Managing Heavy Loads
From construction to cargo, the aerospace industry often deals with payloads that are very heavy and over-sized. Wire rope and cable assemblies are well-equipped to manage these loads. When engineers use jacketed wire ropes, they can also improve safety thanks to their vibrant, eye-catching colors.
External Cargo Systems
Often, aircraft cargo is carried externally. This can also include advanced systems for fighting fires, search and rescue, or medivac where individuals are transported below an aircraft or slowly hoisted into it. Wire rope and cable assemblies provide the strength, stability, and safety to support these systems.
Meeting Industry Demands
The aerospace industry is evolving every day. With advances in technology and increased demand for aircraft and spacecraft, aerospace engineering must continue to innovate. Wire rope and cable assemblies will continue to play a critical role.
From functionality to safety, aircraft cable components provide reliability and performance. As new aerospace technologies emerge, wire rope and cable assemblies will support their success.