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-

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

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: 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: 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.

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-

  1. Conduit
  2. Core
  3. 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 –

  1. Dedicated softened travel path.
  2. Protect against ingress of foreign contaminants.
  3. 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.

Bergen Cable Conduits

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

  1. Braided Conduit
  2. Bowden Conduit
  3. Long Lay Conduit

Bergen Cable Conduit Types

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 catalogue (Bulkhead Fittings, Core Fittings) for more information.

Core

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.

Bergen Cable Push Pull

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

Bergen Cable Pull Pull

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

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

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