Definition and Function

Definition: The brake cable is a mechanical component that transmits braking force, mainly used in vehicles that employ mechanical braking methods, such as bicycles, motorcycles, and some small cars. It consists of a metal inner core and an outer sheath, and the braking action is achieved by pulling the brake cable.

Function: During the braking process, when the driver or cyclist operates the brake lever or pedal, the brake cable transmits the applied force to the brake caliper or brake shoe and other braking components, causing the braking components to make close contact with the rotating part of the wheel, thereby generating friction to slow down or stop the wheel's rotation, achieving deceleration or stopping of the vehicle.

Structure and Composition

Inner Core: The inner core of the brake cable is usually made of multiple strands of high-strength steel wire twisted together, providing high strength and toughness to ensure it can withstand significant tensile forces without breaking. This multi-strand wire structure allows the inner core to transmit force more evenly under load, while also increasing its flexibility, making it easier to install and use in complex wiring environments.

Outer Sheath: The outer sheath is generally made of materials such as plastic or rubber, serving primarily to protect the inner core from external environmental erosion and wear, while allowing the inner core to slide smoothly within it. The outer sheath typically has a certain degree of flexibility and wear resistance to adapt to the various complex conditions faced by the brake cable during vehicle operation.

End Fittings: The two ends of the brake cable are usually equipped with specialized fittings for connecting to the brake lever or pedal and the braking components. These fittings come in various forms, commonly including metal joints, nuts, and clips, which ensure a secure connection between the brake cable and other components, effectively transmitting braking force.

Working Principle

Taking bicycles as an example, when the cyclist squeezes the brake lever, the brake lever pulls the inner core of the brake cable through the lever principle, causing displacement of the inner core. Since the inner core is connected to the brake caliper, the displacement of the inner core is transmitted to the brake caliper, prompting the brake pads of the caliper to tightly grip the wheel rim, thereby generating friction that slows down or stops the wheel's rotation. In motorcycles and some small cars, although the specific braking components and structures may differ, the working principle of the brake cable is fundamentally similar, as it transmits the force from the brake pedal or lever to the braking area of the wheel to achieve braking.

Application Scenarios

Bicycles: Almost all bicycles use brake cables to achieve braking functionality. Whether it is a regular city bike, mountain bike, or road bike, the brake cable is a key component of its braking system. Different types of bicycles may use different types of brake cables and braking methods based on their design and purpose, but the basic principle remains the same.

Motorcycles: In some small motorcycles and certain vintage motorcycles, brake cables are also widely used. Especially in motorcycles that use drum brakes or simple disc brake systems, the brake cable is an important means of achieving braking. With the continuous development of motorcycle technology, although some high-end motorcycles have adopted more advanced hydraulic braking systems, brake cables still play an important role in many mid-range and low-end motorcycles.

Small Cars: Some small cars, particularly certain economy sedans and microcars, often use brake cables in their parking brake systems (handbrakes). When the driver pulls the handbrake, the handbrake lever pulls the braking components of the rear wheels through the brake cable, putting the rear wheels in a braking state to prevent the vehicle from rolling when parked. Additionally, brake cables may also be used in some cars' auxiliary braking systems or special-purpose braking devices.

Maintenance and Care

Regular Inspection: Brake cables should be regularly inspected for wear, breakage, rust, and other issues. This can be done by visually checking the appearance of the brake cable for any damage to the outer sheath or exposed wires. Additionally, check that the connections at both ends of the brake cable are secure and that there are no looseness or disconnection.

Cleaning and Lubrication: During vehicle use, brake cables may become contaminated with dust, oil, and other impurities, which can affect the normal sliding of the brake cable and increase the difficulty of braking. Therefore, it is necessary to regularly clean the brake cable, using a clean cloth or brush to gently wipe the outer sheath to remove surface dirt. Additionally, a suitable amount of specialized lubricant can be injected into the outer sheath of the brake cable to ensure smooth sliding and improve the sensitivity and reliability of braking.

Timely Replacement: If serious wear, breakage, or rust that cannot be repaired is found on the brake cable, it should be replaced with a new one promptly. When replacing the brake cable, it is important to choose a brake cable that matches the vehicle model and to install it according to the correct installation method, ensuring that the brake cable is securely installed and can function properly.