How Mechanical Cables Are Constructed
Cables are the unsung heroes of many mechanical systems, often delivering loads that are incredibly small and under intensely rigorous conditions.mechanical cable They must be small enough to fit in tight spaces, yet robust enough to hold up over the course of their lifetimes. The slightest miscalculation in a cable design can pose risks to expensive equipment or even humans, depending on the circumstances. The throttle pulley in a lawnmower is one example: if the cable were to snap, it could damage other components or cause injury to the operator of that machinery.
The construction of a mechanical control cable starts with the conductors themselves.mechanical cable Conductors are stranded to increase flexibility while maintaining conductivity, and they are insulated with materials like plastic to keep out moisture and other environmental hazards. They may be covered with a specialized coating to improve durability or reduce friction under load.
Once the core and insulation are in place, it is time to add a protective jacket and any other desired features.mechanical cable Connector bodies, sometimes called housings or backshells, are machined out of a material like molded plastic or metal. They can be tin plated for additional corrosion protection, and they are often designed with a contact carrier that holds the cable’s ends together or an impingement screw to hold the cable in place.
Mechanical cable is a complex product, and its assembly requires a great deal of specialized machinery.mechanical cable For example, wire rope and mechanical cable are both produced in massive industrial machines known as stranders, which resemble oversized drums that rotate in a synchronized fashion to twist individual wires fed through them into their familiar helical geometry. The helical construction of cables makes them extremely strong and durable, yet they can also achieve a quotient of flexibility that helps them to reside within a given system while still supporting the load.
Once a cable is assembled, it is tested for quality and performance to ensure that it meets its intended specifications. This testing can involve a number of different procedures, from evaluating the resistance to pulling forces and vibrations to calculating bending moments and torque at supports. The results of this testing are documented in a test report that can be used to determine whether the finished mechanical control cable is suitable for its intended use.
An increasing demand for commercial air travel is prompting aircraft companies to arrange more domestic and international flights, which in turn is driving up the amount of mechanical control cable required by the industry. Aerospace and military applications are another source of mechanical control cable demand, as these cables are used in landing gears and flight control systems, among other things. To meet the demands of these industries, manufacturers must employ skilled engineers who understand the engineering considerations that go into designing mechanical control cables so that they can perform as intended in a wide range of environments. For more information, talk with the experts at Sava.