Providing a Solution to Manual Gear Shift Control Problems for a Leading Chinese Truck Manufacturer

Pain points and challenges

• When the cab of a heavy truck is turned over, the gear selection control can be easily interfered with.

• The control force required for gear shifting in the transmission is relatively large, resulting in unsmooth gear shifting or even inability to select gears, which seriously affects the driving experience.

• In harsh environments such as mountainous areas, the metal parts at both ends of the control flexible shaft are prone to damage, resulting in a significant reduction in product life.

• In complex working conditions such as muddy and oily environments, flexible shafts are prone to contamination and jamming, resulting in issues like inability to pull or delayed action, which severely affects reliability.

Our Solution

Product customization

Customers have very strict performance requirements for the HD series control cables: intermediate stroke control at 8.69 inches, system gap less than 3mm, minimum effective push-pull stroke of 3 to 4 inches, input working load of 600 to 1000 pounds, and maximum overload capacity reaching 900 to 1500 pounds.

To address these complex performance challenges, we have custom-developed the HD series flexible shaft control system. Its structural design takes into account extreme strength, flexibility, and long-term stability, ensuring that even in a cockpit with a 180° flip, smooth gear shifting can be maintained.

1.The HD heavy-duty series is designed with high tensile strength, capable of withstanding a maximum limit pull force of up to 1500 pounds without deformation, thereby ensuring that the shifting operation is not affected.

2.The metal connecting components is made of 304 stainless steel and strengthened through heat treatment, effectively enhancing mechanical stability and fatigue resistance in harsh terrain.

3.The flexible shaft adopts a unique triple sealing structure, combined with various rubber seal materials, which possesses excellent anti-aging and pollution resistance capabilities, ensuring that the system can still operate smoothly in extreme environments such as oil contamination and dust.

Cost Optimization

• The original plan had an average replacement cycle of 6-12 months, while the new plan has extended the service life to 3-5 years, significantly reducing maintenance frequency and substantially lowering operational costs.

• With a maintenance-free design, it reduces daily inspection and lubrication work, truly achieving an "plug and play" operational experience.

• Meeting the stringent requirements of overseas market customers for high reliability and flexible operation has improved overall satisfaction and terminal sales performance, effectively reducing customer maintenance costs.

Results and Benefits

• After years of operation, the reliability and stability of Phidix flexible shaft have been highly recognized by OEM customers.

• Driving flexibility and safety are improved by about 30%, significantly enhancing the driving control experience and road safety.

Competitive Advantage

• It provides customers with strong and sustainable supply chain assurance, maintaining stability in responding to high standards of overseas markets, thereby securing more market share for customers.

• Effectively reduce after-sales maintenance costs, enhance the comprehensive competitiveness of customers in the domestic and international heavy commercial vehicle markets, and consolidate their market leadership position.