Safe-T-Cable
The Complete Fastener Retention System
System Highlights
The Safe-T-Cable® system is comprised of various lengths of high tensile, pre-twisted, stainless steel cable with a fitting at on end, and a ferrule, which may be terminated at any point along the length of the cable. The precision installation tool and its accessories allow the user to verify the calibration, and easily install the Safe-T-Cable® in any location in which it is required.
THE Safe-T-Cable® ADVANTAGE... Standards have been created to define the configuration and performance characteristics of this revolutionary system. Production and maintenance professionals who have evaluated this improved technology agree that is far superior to any method they have previously used. The simplicity of the system is the reason why the user prefers Safe-T-Cable®. The security that it provides is the reason for its preference by the system designer.
THE Safe-T-Cable® VERSATILITY ADVANTAGE... The operator follows a simple procedure, and the job is finished in half the time required to install lockwire.
Safe-T-Cable® MINIMISES REWORK... It is common with lockwire to rework a single installation one or more times due to improper twist pattern, inadequate tension, or other defects. Safe-T-Cable® seldom has to be cut and reworked because the installation tool applies consistent tension to the pre-twisted cable assembly.
Safe-T-Cable® REQUIRES LESS OPERATOR TRAINING... Extensive training is necessary to qualify an operator to install lockwire due to the stringent requirements. A few minutes are all that is necessary to enable an operator to produce high quality Safe-T-Cable® installations.
Safe-T-Cable® MINIMISES F.O.D. IN THE WORK AREA... Installed Safe-T-Cable® can easily be removed in two pieces by simply cutting the cable in half. Discarded cable assemblies can be picked up with the use of magnet sweeps, allowing the work area to remain clean and safe.
Safe-T-Cable® FITS WHERE LOCKWIRE HAS DIFFICULTIES... It can be installed in locations having limited access due to the design of the precision application tool. Often, these areas do not permit access of lockwire twisting pliers and visual inspection equipment.
Tools, Accessories and Verification EquipmentCable Kits, Assemblies and Ferrules
BACKGROUND
Self-locking fasteners are being used extensively in the Aircraft/Aerospace industry. However, there will always be a need to install constraining (safety) devices to many bolts and other threaded fasteners in applications where self-lockers cannot be used. Their purpose is to restrict (to a minimum) the unintentional rotation of the fastener. The traditional method (devised in the early 1900's) is through the use of Hand Twisted Lockwire (often called Safety wire.)
The only changes which have occurred since the early uses of Lockwire are the tremendous costs in the installation of this material, and the levels of sophistication in the systems on which Lockwire is being installed. It is used in Jet Engine systems, Airframes, Electronics, Space Vehicles, and Land/Sea based Systems.
The process of installing remains awkward and costly, and the inspection process is demanding. The removal and rework of installed Lockwire is a common occurrence.
Safe-T-Cable® was invented to address these problems in modern Airframe and Engine Systems. The Safe-T-Cable® Kits are consistent in their construction/application, and the user-friendly tooling guarantees a secure and reliable installation each time it is used. Operator training is simple, Inspection is objective, and rework is virtually eliminated. This results in fewer demands on the Operator, Inspector, and Maintenance personnel.
CONSTRUCTION
Safe-T-Cable® is constructed of high tensile strength, stranded cable. It is more flexible than its Lockwire counterpart, although the working diameters are equivalent. This provides a stronger assembly that has greater strength and lighter weight. The cable ends are electrically fused to form an easy threading end ball.
The cable is pre-cut to various lengths and is supplied with a square-formed end cap attached to one end. Safe-T-Cable® is available in three nominal diameters. The .040-inch diameter cable is constructed of 7x7 stranded rope-lay material. Rope-lay construction is also used for the 3x7 .032-inch diameter cable while the .020-inch diameter cable is made of 1x7 uni-lay material.
The ferrules are precisely manufacturing to a size and hardness that assures their compatibility with the cable and application tooling. They are supplied (50 pieces each) in an easy loading disposable cartridge, which provides orderly containment of individual ferrules, and the easy release of individual ferrules, as they are required. This feature minimises the possibility of Foreign Object Damage (FOD).
TESTING
The application of Safe-T-Cable® is consistent from one installation to the next due to the repeatability and dependability of the application and the quality of the materials used in the manufacture of Safe-T-Cable® Kits. All that is required to assure overall reliability in manufacturing and maintenance use is a periodic test of a few crimped cable assemblies. Glenair offers full instruction and the test equipment to perform these simple tests in either remote or test lab locations.
SAFE-T-CABLE®
The pre-assembled cables have a square formed end cap securely attached to one end. This provides a positive stop when threaded through a fastener. The other end is electrically fused such that it will easily thread through the series of fasteners that are to be secured. The flexible cable material is lightweight and easy to handle. The stainless steel materials will not corrode or deteriorate while in use. (See chart on the following pages for material, size, and part number.) All Safe-T-Cable® kits and assemblies are supplied 50 pieces per package.
FERRULES AND CARTRIDGE LOADING SYSTEM
The individual crimp ferrules are preloaded into disposable cartridge unit (50 pieces per cartridge), which allows convenient transportation, storage, and availability of these components. The ferrules are easily extracted individually by threading the cable end through the ferrule, and snapping the ferrule loose. This system, when properly used, eliminated the possibility of Foreign Object Damage (FOD).
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