Flight Control Wiring Harnesses

It is common for pilots flying commercial or private aircraft to use manual flight controls, but there is a much safer and less costly alternative. This alternative is known as the “fly-by-wire” method. The fly by wire is a system that replaces manual flight control and operates with an electronic interface. What this means is that all flight control movements are transformed into electronic signals that are produced by wires. Flight control computers are then used to determine how to move triggers like the actuator at each control surface.

One such example of a fly by wire aircraft is the F-16. Instead of operating with cables and pulleys, the F-16, like with so many other fly-by-wire aircraft, is controlled by electrical signals that communicate to the flight control surfaces on how to move, as well as how fast it should move. On the F-16, there are 5 flight control surfaces, those being the (1) leading edge flap, (2) trailing edge flaps (also called flaperons), (3) horizontal tail (also called a tailerons), (4) rudder (also called a vertical tail), and (5) speed brakes. The actuators, which are attached to the light control surfaces, receive electrical signals that are sent from the computer via electrical wiring.

Because it is so important that these wiring harnesses do not mix with each other, aircraft maintenance workers are extra vigilant with ensuring their separation. There are four methods for which aircraft maintenance workers can separate wiring harness bundles. These methods include wiring harness bundles, utilizing cable clamps, creating installation paths, and using connectors. In regards to this first method, it simply means that the wires labeled “A” should not be mixed or tangled with wires labeled “B,” “C,” or “D.” Each wire should be in their own wiring harness bundle. As for the second method, aircraft maintenance workers can use cable clamps to help maintain separation between the four cables. In the majority of cases, the four systems should have a cable clamp of a ½ inch or so with at least some distance between clamps.

As for the third method, this is done by separation of installation paths. There are different installation paths for each bundle of cables. It is the maintenance workers’ responsibility to ensure that the installation paths do not cross. This is why you’ll sometimes see that the wiring harnesses for each system runs parallel to one another and are spread apart by a minimum of a ½ inch. Finally, the last method for this includes separation via connectors. What this means is that the wires from the A system should not go into the same connector as the wires for B, C, or D. Much like how different clamps have their designated amount of wires, so too do connectors have their own designated set of wire bundles.

If you’d like to know more about aircraft flight control, feel free to contact the expert team at Veritable Aerospace. Here at Veritable Aerospace, we have over 6 billion Aerospace parts including but not limited to leading edge flap, trailing edge flaps, wiring harnesses, circular cable clamps. As an FAA AC-0056B accredited and 9001:2015 certified enterprise, we take great strides to ensure that each and every part inventoried are checked for airworthiness and the necessary certifications. With some of the quickest lead-times in the industry and supply-chain locations across the US and Canada. we can offer expedited shipping and delivery in a schedule that fits with your needs.

At Veritable Aerospace, owned and operated by ASAP Semiconductor, we can help you find all the unique parts for the aerospace, civil aviation, and defense industries. We’re always available and ready to help you find all the parts and equipment you need, 24/7-365. For a quick and competitive quote, email us at website sales email or call us at website phone number.