Control Cable Application In City Bus

Customer background:

• Industry Application: Shift selection control of bus manual gearbox.

• Area: Zhengzhou City, Henan Province.

• Scale: With an annual output of 200,000 units.

• Requirement:

✓Backlash is less than 2mm.

✓Minimum Travel Push-pull 3”.  

✓Working Input Load 210-400 lbs.

✓Maximum Input Overload 300-600 lbs.

✓Total length from 3 to 15 meters.

✓Manual Transmisssion Shift System 2 pcses.

Pain points and challenges:

• When the manual transmission line is arranged in the middle or rear of the car body, the tension of the control flexible shaft is heavy.

• The idle stroke is 5-8MM, which makes it difficult to change gears and select gears.

• The flexible shaft is easy to get into oil and dust, which causes blockage or even failure to pull.

• Frozen in winter, need to thaw with hot water.

Our solutions:

• Product customization

✓The unique armored structure design enables the flexible shaft to be flexibly wired and easily pushed and pulled even if it passes through multiple S-bends and the length reaches more than 15m.

✓By strictly controlling the matching clearance and the combination of structural rigidity and toughness, there is almost no idle stroke of the short shaft, and the idle stroke of the long shaft over 10 meters can also be controlled within 2 mm.

✓Triple seal is adopted, and the surface of the end rod is also polished by mirror, which forms a tight fit with the seal, effectively preventing dust and oil pollution from entering the interior of the shaft sleeve.

✓The sheath, lining and grease are made of special materials with low temperature resistance, which can achieve perfect operation at MINUS 60 degrees and effectively solve the embarrassment of thawing with boiling water in maintenance.

• Cost optimization

✓The improvement of product performance will effectively prolong the service life and reduce the cost of replacement and maintenance.

✓Maintenance-free design makes the internal grease effective for a long time, without regular maintenance and replacement, saving a lot of labor and shutdown costs.

✓Flexible wiring saves designers a lot of redundant design and trial and error costs.

✓High performance brings about the improvement of vehicle performance, good handling experience for drivers, improved vehicle safety performance and reduced potential losses.

Results and benefits:

• The project has been implemented for more than 20 years, ensuring the leading position of OEM customers in the market.

• The stability of handling performance guarantees the quality stability of the whole vehicle.

• Long-term framework cooperation agreement, from the initial implementation to the present, has built a stable supply chain cooperation relationship.

• The development of overseas markets and excellent shift control have made great contributions to OEM customers to consolidate their leading position in the world market.