Control Cables

Control cables are mechanic motion transmission cables used to relay the required signal/action from the operator to the specific control point. Control cables due to the attribute of their application require them to be:

Precise in Action
Suited for the environment (sub-zero temperatures/corrosive/dirt-dust prone/oil-submerged etc.)
Easy to mount/dismount in complex restricted space
Flexible to be adjusted/recalibrated in its operational lifetime

As an industry leader in manufacturing control cables, Bergen Cable has the capabilities to produce control cables suited to a diverse range of applications. Contact us today to talk about your specific application.

These multiple and diversified requirements necessitate the manufacturing of control cables from a vast variety of materials and components and require diverse manufacturing capabilities to produce the bespoke customized cables suited to specific applications. Bergen Cable manufactures control cables enriched with over 75 years of Bergen Cable’s experience in wire rope and cables assembly. Control cables are classified by virtue of their mechanical action, i.e. PUSH-PULL and PULL-PULL Cable.

Push-Pull Control Cables

PUSH-PULL: In a Push-Pull control cable, the motion applied by the operator is by compression/push action in one direction, and the motion is transmitted in the opposite direction as a tension/pull force.

Pull-Pull Control Cables

PULL-PULL: In Pull-Pull control cable, the motion applied by the operator is by tension/pull action in one direction, and the motion is transmitted in the opposite direction is also sequentially of Pull force. The control cable returns to its neutral/original position by spring actuation.

Have questions? Contact us today to discuss your control cable needs.

Control Cables Manufacturing

To understand the control cables manufacturing and user selection, it’s important to look at the sub-assemblies of the Control cables. The control cable can be subdivided into the following components-

Conduit
Core
End Fittings

Conduit

Conduit is the sleeve that provides the dedicated travel path for the control cable core facilitating the routing of control cables in intricate non-linear applications. Conduits serve many purposes such as they help increase the service life of control cables and maintain the precision motion transmission and are crucial to the successful design of the control cables, for example, it serves as –

Dedicated softened travel path.
Protect against ingress of foreign contaminants.
Resist abrasion/corrosion.

Conduits consist of the following subassemblies: a liner (through which the core cable runs), a wrap (provides the flexibility and protection to the cable assembly), and a jacket (act as a sealing layer against external environment), as shown in the figure below.

The conduits for these cables can be of the following three types, and their selection is dictated mainly by the application environment.

Braided Conduit
Bowden Conduit
Long Lay Conduit

Bulkhead Fittings / Core Fittings

The selection of bulkhead fittings, core fittings, end fittings, and intermittent transmission fittings is based on the application (Push-Pull, Pull-Pull), the length of the cable, and the path that the control cable is routed through. Based on the user requirements, these fittings can be made custom to the application. Please refer to the Bergen cables catalog (Bulkhead Fittings, Core Fittings) for more information.

Core Cable

The core cable is the one that transmits the motion and is travelling in the conduit. Based on the operation type Push-Pull, Pull-Pull the core cable can be either stranded or solid.

Push-Pull: Control cable cores are preferably made with a solid core.

Pull-Pull: Control cables cores are preferably made with the stranded core.

Control Cable Applications

Control cables see the application in varied industry bases for their ease of application, repair, and maintenance. Some of the known applications of control cables are-

ATVs
Utility Vehicles
Wheelchairs
Construction Vehicles and Equipment
Outdoor Power Equipment
Helicopter Systems
Medical Equipment
HVAC Controls
Fixed Wing Aircraft Systems
Industrial Systems
Military Vehicles and Equipment

Precision Control Cables for Reliable Motion Transmission

Control cables play an important role in systems where mechanical motion must be transferred accurately from an operator to a remote control point. These assemblies must perform flawlessly in environments that range from sub zero temperatures to corrosive industrial settings, all while maintaining smooth, predictable motion. Bergen Cable supports these demanding requirements with engineered control cable solutions designed for precision, durability, and long term serviceability.

Engineered for Demanding Operating Conditions

Every control cable must balance strength, flexibility, and environmental resistance. Bergen Cable designs assemblies that maintain consistent performance even when routed through tight spaces, exposed to contaminants, or subjected to repeated adjustments over their operational life. Our engineering team selects materials, conduit types, and core constructions based on the specific mechanical action required, ensuring each cable delivers reliable push pull or pull pull performance.

Custom-Built Assemblies for Specialized Applications

With more than 75 years of experience in wire rope and cable assembly, Bergen Cable manufactures control cables tailored to the needs of diverse industries. Our capabilities include custom conduit construction, precision formed end fittings, and core cables engineered for the required load and motion characteristics. Whether the application calls for a solid core for compression based actuation or a stranded core for flexible tension only systems, each assembly is built to meet exact performance criteria.

Components Designed for Precision and Longevity

A control cable’s performance depends on the quality of its sub assemblies. Conduits are engineered to protect the core from abrasion, contaminants, and environmental exposure while providing a smooth travel path. End fittings are selected or custom designed to match the mounting requirements and mechanical loads of the system. Each component works together to ensure accurate motion transfer and long service life.

Versatile Solutions for Multiple Industries

Control cables are used across a wide range of equipment and vehicle platforms due to their reliability and ease of integration. Bergen Cable supports applications in mobility equipment, off road vehicles, aerospace systems, industrial machinery, HVAC controls, medical devices, and military platforms. Our ability to customize materials, geometry, and performance characteristics makes us a trusted partner for OEMs seeking dependable mechanical control solutions.

Frequently Asked Questions

What Types of Control Cables Does Bergen Cable Manufacture?

We design and produce both push pull and pull pull control cables, each engineered for specific mechanical motion requirements and environmental conditions.

How Are Control Cable Components Selected?

Material choices, conduit types, and end fittings are determined by factors such as load, routing path, temperature, and the type of mechanical action required.

Can Bergen Cable Produce Custom Control Cable Assemblies?

Yes. We specialize in custom engineered assemblies tailored to unique applications, including specialized fittings, conduit constructions, and core cable designs.

Which Industries Use Bergen Cable Control Cables?

Our control cables are used in aerospace, medical equipment, off road vehicles, industrial systems, HVAC controls, mobility devices, and military platforms.

For more information on your needs and custom design of your control cables, please reach out to us!