In the wiring and electrical industry many types of wires and connectors are used for connecting electrical and mechanical equipments. The clamps or connectors used for connecting two electrical devices are called as electrical lugs. Use of cable lugs allows supply and distribution of electric current without any hindrance between electrical cables. Electrical lugs are used when permanent connection is not possible between devices or cables.
Use of cable lugs allows in easy installation, repair and maintenance of electrical devices or cables. Most common use of lugs includes connecting one cable with another cable or connection more than two cables. It is also used in connecting fuse sockets, load switches and electrical appliances, other than for connecting cables and power lines. To connect high voltage passing cables or electrical connections a special type of compression lug is used. As lugs are used for connecting electrical devices and cables, most of such connectors are available in rubber or plastic insulated sheets. This ensures safe handling.
Usually one end of the electrical lug is used for connecting a cable to an electrical device. This end is crimped or welded or soldered on the cable to ensure it is connected correctly and tightly. The other end of the lug is attached to the connection terminal of the electrical device. When connecting to the connection terminal, a bolt or screw is used to fasten it on it. Spring clip is used for connection purpose. Use of cable lugs differs based on usage and industry.
Cable lugs of various sizes, shapes, materials and configuration are used in the industry. In the wiring, automation, control panel and instrumentation industry, insulated lugs with pin terminal, blade terminal, hook terminal, fork terminal and ring terminal are used. For multiple connection purposes copper ring type lugs are commonly used. Many of the devices are connected with cables using Copper cable lugs.
Another type of lug is butt and parallel connector. This is mostly used for connecting and terminating 2 cables. Some of the widely used butt and parallel connectors are pvc insulated, butt type, heat shrinkable and closed end type. Most of the industries where cables are commonly used to connect equipments use butt and parallel connector. It is available in different sizes, shapes and materials Copper cable lugs are used as butt and parallel connector depending on the type of cable used to connect a device with the other.
In the power distribution industry, tube crimping lugs are used. As high voltage power is passed, most of the connectors used for connection purpose have a thick layer of insulation. Some use copper tubular lugs. Material of the lug should be chosen based on the usage.
In the wiring and electrical sector, lugs have indispensable usage. Strength of a lug should be checked before using it in the heavy-duty applications. In many applications the strength and the shape of lugs matters. Select lugs based on the usage.
Compression connections require matching of compression cable lugs, conductors and tool size. That will provide best results: a durable, reliable connection.
All compression cable lugs are stamped with cross section specification.
Select the compression tool die corresponding to this size.
The hexagon compressions are carried out by means of mechanical, hydraulic or electrical tools.
“Cu” marked dies have to be used for copper compression cable lugs.
“Al” dies are used for aluminum or aluminum alloy compression cable lugs.
In the case of hydraulic tools differentiation regarding the conductor materials is not necessary.
Strip conductor to sleeve length l+10%
Remove all tapes/yarn/powder or similar conductor filling materials before mounting
Erase dirt and oxide layers from both conductors using a metal brush
Insert conductor into compression sleeve up to the stop or inspection hole
Before compression verify the die code with the compression mark on the joint
Start compression from the middle to the barrel end
The number and position of the compression points is indicated by marking lines. Attention: All markings must be compressed
Insert second conductor into compression sleeve up to the stop or inspection hole
Start compression on second side from the middle to the barrel end
Final Check: The extension length of the joint is about 10 % by proper compression with correct conductor – joint – die – combination
Remove excess grease
Q & A
FREQUENTLY ASKED QUESTIONS
HOW ABOUT YOUR RAW MATERIAL? Conecteur use high-purity copper raw materials, better electrical conductivity, and better energy savings.
HOW TO CHOOSE FROM DIFFERENT TYPES? Different markets have different standards and habits, please refer to your local standard or contact us.
HOW ABOUT YOUR MACHINES? Automatic equipments effectively protect the stability of every parameters during production process, ensure a stable quality.
HOW ABOUT YOUR QUALITY? Sampling inspection of each process and finished-products, ensuring the quality reliability of each batch of products.
HOW ABOUT YOUR SURFACE TREATMENT? Avoiding oxidation on surface, both bright and dark tin-plated is aviable for terminal lugs and terminal connectors.
HOW TO CHOOSE CRIMPING TOOLS? Matching crimping tools and dies ensure good crimping quality and reliabe cable connection. KINGO supply related tools on request.