What to consider when assembling aerospace cables

Cables have become essential to many industries today but aerospace is a sector that requires them more than most. Some aircraft need more than a hundred miles of cables in just a single plane. Cables come into play in many different ways in aerospace and each one must meet individual and precise specifications when it comes to factors such as weight and safety requirements. The more effectively cables have been designed the better the aircraft will function and the more improvements can be made in key areas such as fuel consumption, plane weight and speed. The process of cable assembly for aerospace can be complex and detailed and there are a number of key elements to consider.

• Cable and assembly weight. Even the slightest additional weight can have an impact on how an aircraft flies so this is a big consideration. Small decisions can be vital, for example choosing to use cables that have a higher temperature rating because they contain less copper and are lighter can help to reduce the weight of an aircraft overall.
• The environmental conditions in an aircraft can be a challenge for any material, whether that is extreme heat or dryness, cold or humidity. Cables may also be exposed to high levels of fluids, abrasion and vibration so need to be assembled with resilience to extreme environments in mind.
• It’s essential that cables have been designed to cause minimal damage in the event of a fire. So, they should emit minimal smoke and dangerous gases – if this has not been taken into account then, given the miles and miles of cabling in most aircraft, the results could be catastrophic.
• Easy to mark. It’s essential that cables are capable of being marked and are smooth with the ability to attach to labels. This is especially key because there are so many cables inside an aircraft and it simply wouldn’t be possible to make a note of the individuality of each one separately.
• Durability in the case of an overload situation. Overload conditions can mean that a lot of pressure is being transferred to the cables within an aircraft and it’s essential that, if that happens, the cables that are in place can continue to maintain circuit integrity.
• Meeting standards for Electromagnetic Interference. There are a number of guidelines in place to ensure that this happens, including that cables use filtered connectors, employ minimum braided shielding and maximise use of foil, shield the cable signals and minimise the transfer impedance, and use twisted data signal wires to help cancel out emission fields.

Aerospace cables are some of the most crucial components of any aircraft and can have a big impact, not just on how a plane functions, but also how safe it is to fly. So, it’s not surprising that there is such a wide range of considerations to bear in mind when it comes to assembling aerospace cables. From weight and durability to resilience and flammability, it’s essential that all these are taken into account. We are one of the UK’s leading cable manufacturers for aircraft, aviation & aerospace markets, contact our sales team today about our aerospace cable assemblies…