This article contains information regarding push pull cable controls and their use.
You will learn more about topics such as:
A push-pull cable control is crafted for accurate, multi-directional mechanical motion management. Available in several variations, these controls are versatile for numerous applications. Widely utilized in automotive, aerospace, and heavy machinery sectors, push-pull assemblies aid in adjusting and maneuvering different mechanisms.
These cable systems feature two specific cables: one engages a device, while the other disengages it. Despite its designation as a "push" cable, it essentially functions by pulling, similar to the second cable, which also relies on pulling.
Though push-pull assemblies fulfill a basic objective, they are integral to the development and design of mechanical components and analog systems. For actuating equipment using physical force, utilizing a push-pull control cable is frequently the ideal solution.
Designing push-pull assemblies begins with assessing the workload in the push mode. The inner wire might face resistance, leading to bending or buckling, particularly when protruding beyond the conduit. Enhancing the inner wire's diameter can address this concern, enabling it to endure the workload effectively.
In the creation of push-pull assemblies, engineers must weigh several considerations, including the behavior of the inner wire in the push mode. While the operation of these assemblies is fundamentally simple, ensuring precise and accurate calculations is vital for their optimal performance.
The design and manufacturing of push-pull assemblies are essential for effective machine design and reliable performance in numerous industries. A well-engineered push-pull assembly, also known as a push-pull control cable or control cable assembly, ensures powered mechanical or electromechanical functions operate smoothly with enhanced safety, precision, and extended service life. These assemblies play a critical role in managing equipment functions such as acceleration, actuation, braking, choking, drive latches, hood releases, rotation, and throttling mechanisms, making them vital components in the automotive, industrial machinery, marine, and aerospace sectors.
During the design phase of a push-pull assembly, engineers must pay meticulous attention to each component and material selected. Any defect or inconsistency in assembly construction can significantly impact overall system performance, reliability, and safety. Although there are specialized types of push-pull assemblies—ranging from flexible drive cables to custom control cable assemblies—several key components and production techniques are common to all assembly types and applications.
The casing of a push-pull assembly, also referred to as the conduit, provides a protective pathway for the inner cable or core wire. The conduit ensures that the inner cable is properly guided and shielded, even in challenging operating environments. Manufacturers produce casings from a variety of materials—including galvanized steel, nylon, plastic tubing, or spiral-wrapped wire—based on the application’s requirements for flexibility, abrasion resistance, chemical resistance, and strength. High-performance plastic or steel casings are often used in applications exposed to vibration, extreme temperatures, or corrosive elements.
The casing features a carefully engineered inner diameter that houses the moving cable, while its outer diameter is designed to provide the necessary mechanical strength and durability. Specialized end fittings can be added to the casing to enhance the assembly's operational ease and ensure a precise interface with user controls, levers, or actuators. A well-manufactured conduit reduces friction, prevents cable kinking, and increases the lifespan of the push-pull assembly.
The bulkhead terminal is securely crimped or swaged onto the casing, providing robust anchoring for the push-pull control cable to a panel, bulkhead, or other solid surfaces within machinery or vehicles. Bulkhead terminals are typically manufactured from high-strength materials such as steel, stainless steel, or brass to withstand demanding loads and resist corrosion in industrial or marine environments. Correct installation of the bulkhead terminal ensures accurate cable actuation and prevents unwanted movement, which is particularly important in safety-critical applications.
Choosing the proper inner wire, sometimes called the control cable core, is fundamental to push-pull assembly performance. Even in light-duty applications, a robust inner cable is required for smooth and reliable actuation. The selection of cable material—usually stainless steel or galvanized steel—depends on its mechanical properties, including tensile strength, corrosion resistance, and flexibility. The pull position, where the greatest loads occur, largely determines the appropriate cable configuration and size.
Flexibility is another critical factor in the cable's design. Most high-quality push-pull assemblies utilize 7 x 19 or 7 x 7 cable configurations, which offer optimal bending capability without sacrificing strength, making them ideal for complex routing paths or compact mechanical designs. In contrast, 1 x 19 wire provides higher rigidity but is used less frequently when flexibility is required.
Managing friction within the casing or conduit is key to maximizing assembly longevity and minimizing wear on the core. For this reason, uncoated wires are commonly used, as they yield lower friction compared to coated alternatives. This design choice enhances assembly durability, reduces downtime, and lowers maintenance costs for end users.
It is important to consider the cable’s travel distance, or the span between the conduit end and the cable's bearing surface. Keeping travel distances short—ideally under five inches—reduces cable friction, prevents core buckling, and helps maintain consistent, responsive cable operation.
Inner wires are manufactured by winding fine strands in a helical pattern around a central core—for example, a 7 x 7 cable comprises seven strands, each with seven wires. Cables with higher strand and wire counts provide increased flexibility and load handling capabilities, making them suitable for dynamic control applications. In some cases, solid core wires are chosen for push-pull applications where both modes of movement—or where added cable stiffness—are essential for precise mechanical actuation.
Fittings and terminals are critical elements at the ends of a push-pull assembly, providing secure connections and preventing system deflection or loss of cable tension. These cable ends enable technicians or operators to adjust, actuate, accelerate, regulate, and release mechanisms with accuracy and safety. The appropriate end fitting is determined by the assembly’s application—whether for throttle controls, transmission linkages, industrial equipment, or marine steering systems—and ensures the cable’s precise interface with levers, switches, or mechanical linkages.
Stamped eyes are widely used cable terminals designed for compatibility with a range of control cables and linkage attachments. They are pressed and fixed using hydraulic swaging equipment—ensuring a strong, vibration-resistant connection suitable for automotive, agricultural, and industrial control applications.
Ball end fittings are engineered to match diverse cable diameters in throttle, brake, or shift control systems. Swaged onto the inner cable, ball ends provide smooth pivoting action and secure connection to levers or control arms, helping to optimize system responsiveness and reliability.
Ball shank fittings serve in numerous push-pull cable assembly applications, from throttle and clutch controls to marine steering and exercise equipment. By shielding the cable from abrasion and providing a pivot point, ball shanks facilitate smooth cable rotation, extend cable service life, and reduce mechanical wear in high-use scenarios.
Thimbles are incorporated when forming loops at the end of cables, playing a vital role in preventing wear and maintaining loop integrity. These robust end fittings protect the inner cable from sharp bends and abrasion, which is particularly important in lifting, rigging, and heavy-duty industrial control systems.
Threaded studs enable the direct attachment of a push-pull assembly to machine fixtures or adjustment mechanisms. Available in multiple thread sizes and styles, these fittings are swaged onto cables to create a rugged and reliable interface, commonly seen in manufacturing equipment, automotive controls, and instrumentation linkages.
Strap fork and eye fittings are essential for pull actuation in conjunction with pins or bolts. Strap forks permit direct link actuation in forked assemblies, while strap eyes provide straight or rigid connections in high-load scenarios. Their slim profile—often achieved through welding—makes them ideal for compact machinery, automotive linkages, and tight-space industrial equipment.
Marine eye fittings are specifically engineered for the boating, yachting, and maritime industries. Crafted from grade 316 stainless steel for maximum corrosion resistance, these fittings deliver durability in saltwater and harsh marine environments. Their polished finish and rugged construction fulfill aesthetic and performance criteria, explaining their higher cost and longer service life compared to standard control cable ends.
Handle and knob end fittings are standard in a wide array of garden and outdoor power equipment—such as lawn mowers, snow blowers, and chainsaws—where they act as ergonomic actuators for making adjustments, initiating rotation, releasing locks, or accelerating engines. These components are engineered for user comfort, slip resistance, and control feedback to ensure safe and effective operation.
The end fittings, cable terminals, protective caps, handles, and knobs described above represent only a portion of the diverse configurations available. Many specialist push-pull cable assemblies incorporate custom connections and fittings—such as quick-release latches, adjustable stops, or high-temperature insulators—meticulously tailored to satisfy unique operational, environmental, and regulatory requirements. Working with a reputable push-pull assembly manufacturer ensures your control cable system is expertly engineered to deliver safety, reliability, and optimal performance in any industry setting.
When selecting a push-pull assembly or control cable assembly for your application, several factors must be considered to ensure optimal performance and longevity. Consider the environmental conditions—such as exposure to chemicals, moisture, extreme temperatures, or vibration—along with the required load capacity, cable routing complexity, application-specific regulations, and maintenance requirements. Leading push-pull cable manufacturers offer a variety of standard and custom cable solutions to meet the precise needs of industries ranging from automotive manufacturing and heavy equipment to avionics, rail transit, and medical device assembly.
Work closely with a knowledgeable manufacturer or distributor to select the correct cable size, core construction, conduit material, required end fittings, and mounting options. By providing information on your application's operating parameters and desired actuation characteristics, you can ensure your push-pull control assembly delivers the highest levels of quality, consistency, and cost-efficiency. For additional guidance, consider consulting product catalogs, technical data sheets, and engineer support teams at reputable control cable suppliers.
Push pull cable controls have diverse applications across numerous industries, from complex aerospace systems to everyday gardening tools. They are engineered to manage processes, adjust mechanisms, and activate various components during operation.
With the advent of the computer age, it could be assumed that push pull cable controls would no longer be necessary. In actuality, push pull control cables have become essential for programming automated equipment. The versatility and adaptability of push pull controls and their ability to perform accurately and flawlessly have made them ideal for the many computer run functions.
Modern aircraft demand reliable components to ensure safe control and optimal performance. Push pull cable controls enable remote activation of aircraft mechanisms, providing the necessary precision and dependability.
Aircraft components must withstand high tension and compression forces experienced during flight, making push pull cable controls an ideal solution. For aircraft applications, these controls are typically manufactured in short lengths to minimize vibration and prevent bending under compression.
Push pull controls are widely used in boats to mechanically connect the control head to the clutch and throttle. They are especially effective for boats with one or two control stations and cable lengths of less than 50 feet. In a single-lever control system, pushing the lever forward engages the clutch, while continuing to push increases the speed. Pulling the lever back reverses these actions, reducing speed and disengaging the clutch.
In lawn mowers, push pull control cables function as throttle cables to regulate the engine speed. Modern lawn mowers connect these cables directly to the carburetor's intake valve. The maximum push load for a throttle cable is 10 lbs, while the pull load can reach up to 25 lbs.
Heavy duty equipment, such as trucks, rely on push pull control cable assemblies to activate several operations and processes. There are cables for front winch control, dump body control, shift control, transmission engage control, defrost control, engine stop, and throttle control, to name a few. These different push pull control cables make operating heavy duty trucks easier and more efficient.
The examples of push pull control cables provided here represent just a small fraction of their many applications. These cables are utilized in industrial machinery, automated systems, construction equipment, and numerous other fields. Their ability to activate and control processes with accuracy and precision is what makes them so versatile and widely used.
Push pull control cables are at the heart of motion control systems. In the production of cable assemblies, certain factors have to be considered such as the workload in the push and pull modes, where the workload in the push mode is the most critical. Other design considerations are abrasion, cycle life, flexibility, the environment, and safety.
The versatility and reliability of push pull cable controls often make them a preferred alternative to electronic, hydraulic, and pneumatic systems. Various installation methods are employed for push pull control cables, depending on the specific application, structural considerations, and accessibility.
The most widely used installation method for push pull cables is the rivet technique. This usually involves placing two rivets at right angles at each end of the mechanism. Special attention is needed when dealing with rod ends that have hollow shanks. Depending on the situation, rivets may be inserted with a rivet gun or manually hammered into place.
Securing push pull cable assemblies using bolts and nuts involves selecting bolts that can handle the assembly’s tension and compression. The size and strength of the bolts are chosen based on the dimensions of the push pull assembly, with larger assemblies needing more robust bolts. Typically, fiber or nylon lock nuts are used to secure the connections, as they provide locking capabilities to prevent loosening due to vibrations.
Welding push pull cable controls is a method applied to assemblies constructed from steel or stainless steel. This technique provides a secure attachment of the assembly, though it demands a high level of expertise and careful attention to ensure accurate placement and proper fit.
For shorter push pull cable controls, particularly those around eight to nine inches in length, threaded fittings are highly effective. This method enables adjustments at both ends of the rod, although typically, only one end remains fixed. The key benefit of adjustable ends is the flexibility to make a broad range of modifications and fine-tuning.
When dealing with push pull cable assemblies, calculating the workload is crucial for ensuring the mechanism functions correctly. This factor represents the force needed to operate the device.
The primary focus is on the pushing mode, which handles a heavier load. Adjusting the cable diameter can accommodate increased workload in the push direction. On the other hand, the pulling workload is more adaptable and can be adjusted with greater ease.
Backlash refers to the motion lost during the actuation of a push pull cable. This factor is typically considered during the design stage but can be adjusted by increasing the number of bends and tightening the bend angles. Reducing the number of bends and angles helps minimize backlash and improves overall performance.
Each push pull control cable installation is tailored to its specific application. The four connection methods discussed are just a few examples. The installation approach depends on the types of fittings used and the installation location of the cable.
Considerations such as backlash, vibrations, abrasions, and workload are relevant to all push pull control cable installations and are usually addressed during the design process. However, these factors should also be evaluated during the assembly's operation. The most important aspect when selecting push pull controls is the quality and reputation of the manufacturer, which can significantly mitigate future issues.
An aircraft cable is a style of highly durable cable that is used for aircraft flight controls and other applications and is differentiated from normal cables by its diameter, stranding, and wires, which provide...
Stranded wire refers to thin bundled up wires that are compressed and covered up in insulating material. Stranded wires are more flexible thus making them very ideal for joining electronic circuit components in confined spaces where their bending...
Wire rope is a collection of metal strands that have been twisted and wound to form the shape of a helix with the purpose of supporting and lifting heavy loads and performing tasks that are too rigorous for standard wire...
A wire rope assembly is composed of wire rope and end fittings, terminals, or lanyards that are attached to various parts of the wire rope such that the assembly can be used to lift, hoist, and move loads. The various types of...
Wire rope is constructed of multiple strands of wire that are twisted and braided together to form a spiral design or helix. Once the separate wires are shaped into a solid form, they become a single wire with greater strength because...
A bungee cord is a rope that is composed of two or more elastic strands coated with a woven fabric. It has hooks that are placed on both ends. A bungee cord is also known as shock cord and elastic cord...
Cordage is a series of intertwined fibers, strands, strings, or fabric that are joined by twisting or braiding to form a larger more formidable whole. The combination of the materials makes the final, larger strand stronger than its individual pieces...
Electric hoists are material handling equipment used for lifting, lowering, and transporting materials and products. They are powered by an electric motor and have a controller to adjust the lifting parameters...
A gantry crane is an overhead crane that has an overhead beam supported by freestanding legs and moves on wheels, a track, or rail system carrying a bridge, trolley, and hoist. Workshops, warehouses, freight yards, railroads, and shipyards use gantry cranes as their lifting solution as a variation of overhead or bridge cranes...
Rope is a collection of strands, fibers, piles and yarns joined together to form a strong and a large structure. These strands or fibers are either twisted or braided with one another to give high tensile strength to the rope...
A hydraulic lift is a device for moving objects using force created by pressure on a liquid inside a cylinder that moves a piston upward. Incompressible oil is pumped into the cylinder, which forces the piston upward. When a valve opens to release the oil, the piston lowers by gravitational force...
A jib crane is a lifting device with an arm or boom that extends off the main body of the crane to provide extra reach and has a lattice design to lower the weight added to a load. The design of jib cranes allows them to work...
A lift table is a platform capable of holding materials and raising, lowering, and adjusting them to any height to meet the needs of an application and the user’s requirements. Lift tables are supported by a strong, rigid, and stable base frame placed flat on the floor, in a pit, or equipped with casters or wheels...
An overhead crane is a type of heavy duty machinery that is capable of moving extremely heavy loads and equipment from one location to another in a safe and precise manner using the overhead space of a manufacturing facility. Due to the nature of the work they perform...
Scissor lifts are a type of manlift that is commonly used in construction and facility maintenance to raise employees and their tools to working heights. A power system and a control system make up the scissor lift...
A hydraulic system is based on Pascal‘s principle of fluid pressure, which hypothesizes that a change in pressure in a fluid is transmitted to all points of the fluid in all directions. With a hydraulic lift, an electrically powered pump pushes fluid into a cylinder at the base of a lifting jack system that lifts the platform up and down...