Control cables are vital components in the defense industry, enabling precise transmission of mechanical motion in high-stakes environments where reliability and durability are non-negotiable. Bergen Cable Technology, a leader in wire rope and cable assemblies since 1942, specializes in manufacturing custom control cables, including push-pull and pull-pull configurations, tailored to meet the stringent demands of defense applications. These cables ensure seamless operation in military equipment, from aircraft to ground vehicles, enhancing safety and performance under extreme conditions.
Understanding Control Cables
Control cables are mechanical systems designed to transmit motion or force from an operator to a specific component. Bergen Cable classifies them into two main types: push-pull and pull-pull. In push-pull cables, motion is applied through compression in one direction and tension in the opposite, ideal for applications requiring bidirectional control. Pull-pull cables rely solely on tension in both directions, offering simplicity and reliability for specific functions. These cables consist of a core (stranded or solid), a conduit for routing, and fittings like bulkheads or end terminals, all customized to the application’s requirements.
Applications in the Defense Industry
In defense, control cables are integral to various systems, ensuring precise operation in critical scenarios:
- Aerospace and Aircraft Systems: Military aircraft, such as fighter jets and helicopters, rely on control cables for flight control surfaces like ailerons, rudders, and elevators. Bergen’s Mil-Spec aircraft control cables are lightweight, strong, and flexible, meeting rigorous standards for vibration resistance and extreme temperatures. Their Safety Cable™ system, developed with General Electric Aircraft Engines in 1988, replaces lock wire to secure fasteners in high-vibration areas like engines and landing gear, reducing installation time by 50% and minimizing foreign object debris (FOD).
- Ground Vehicles: Tanks, armored vehicles, and military trucks use push-pull control cables for throttle, brake, and steering systems. These cables withstand harsh conditions, including dust, moisture, and temperature extremes, ensuring reliable performance in combat zones. Bergen’s custom fittings and durable materials like stainless steel or galvanized carbon steel enhance longevity and corrosion resistance.
- Naval and Marine Applications: Control cables are used in naval vessels for steering, throttle control, and weapon systems. Marine wire ropes, designed for mooring and anchoring, must resist corrosion from saltwater exposure. Bergen’s cables, available in materials like Inconel 625 for superior corrosion resistance, ensure operational integrity in maritime defense operations.
- Missile and Weapon Systems: Precision control cables are critical for guiding missile systems and actuating weapon mechanisms. Bergen’s miniature cables, such as Microlin™ and Posilign™, with diameters as small as 0.010 inches, provide flexibility and strength in compact spaces, ideal for intricate defense applications.
Why Control Cables Matter in Defense
The defense industry demands components that perform flawlessly under stress. Bergen Cable’s control cables meet these needs through:
Durability and Reliability: Materials like 304 and 321 stainless steel or Inconel 600 ensure resistance to corrosion, high temperatures, and fatigue, critical for prolonged use in harsh environments.
Precision Engineering: Bergen’s use of Finite Element Analysis (FEA) optimizes cable designs for minimal friction and precise motion control, ensuring accurate responses in mission-critical systems.
Customization: With over 75 years of expertise, Bergen tailors cables to specific defense needs, incorporating custom fittings and conduits to navigate complex routing paths.
Compliance and Quality: Certifications like ISO 9001:2015, AS9100D, and multiple Boeing awards reflect Bergen’s adherence to stringent defense standards, ensuring reliability in high-stakes applications.
Challenges and Innovations
Defense applications face challenges like vibration, extreme temperatures, and space constraints. Bergen addresses these through innovations like the Safety Cable™ system, which reduces FOD risks, and Lockclad cables (MIL-DTL-87218), which minimize stretch and abrasion in aircraft control systems. Their in-house CNC machining and testing capabilities, including pull tests up to 22,500 lbs, ensure precision and quality control, reducing lead times and enhancing reliability.
The Bergen Advantage
Bergen Cable, headquartered in Fairfield, New Jersey, leverages its Made in the U.S.A. commitment to deliver faster lead times and exceptional customer support. Their engineering team collaborates closely with defense contractors to design cost-effective, reliable solutions, from concept to production. With a history of serving aerospace, defense, and marine sectors, Bergen’s control cables are trusted by industry leaders for their performance and compliance with military specifications.