Cable Lugs
Cable lugs are a component of electrical systems used to ground devices, connect cables to terminals/conduits and to terminate electrical circuits. They can also be used in emergency situations in order to rapidly connect wiring. The lugs attach to the end of cables in order to prepare them for interfacing with spring or screw type connectors, such as those found on electrical panels or circuit breakers.
Cable lugs can be made of either copper or tin-coated copper. The latter is often used in areas with unfavorable environmental conditions and adverse climate, where high durability is essential for protection from the elements. In such cases, the tin coating provides a protective barrier from reactive chemicals and oxidation. This being said, cable lugs manufactured from copper are also durable and are a reliable component in electrical systems
The copper used to manufacture cable lugs is purified to the standards required to operate in electronic systems, therefore it exhibits a high level of corrosion resistance and conductivity. The design and features of the cable lug prevent the detrimental effects of galvanic vapors and minimize the possibility of the cable end having incomplete contact with the device.
Our cable lugs differ from our competitors by a high level of durability, reliability and safety when used in electrical systems. The type of lug is typically chosen based on the size of the conduit or device they are intended to interface with; complete compatibility will guarantee a reliable system. The lugs can also differ in shape and type of connector, which allows for flexibility in controlling the electrical system. The mounting process of cable lugs utilizes specialized tools and instruments as well as crimping devices.
Types of Cable Lugs/Connectors
Cable lugs can be classified via the following parameters:
1.Material:
- Aluminium for crimping
- Copper (Tin-Coated or Standard) for soldering or crimping;
- Combined metals (Aluminium and Copper), consisting of a copper connector and an aluminium tube
Although copper lugs can be prepared for crimping; aluminium lugs are more commonly used for this purpose for cores with a cross section of 16mm sq.
The lugs are labeled according to their constituent material: ТМ or ТА (Copper and Aluminium respectively).
Tin-coated copper lugs are often used for cables with multi-wire cores, where the connecting end of the lug is compressed and drilled for attachment using a bolt or screw.
The lugs can come with (ТМЛ) or without (ТМ) electrolytic tin coating.
Combined metal lugs (ТАМ) are the most commonly used type of cable lug as industrial electrical circuits typically require an aluminium cable to be connected to a copper based connectors on conduits and main circuit-boards; This type of connection is achieved absent of transfer resistance through utilization of frictional diffusion.
All cable lugs are marked using a standardized system: Mark-АА-BB, Where АА - Cross section of the lug, аnd BB - Diameter after compression when attached with a bolt or screw.
2. Type of Connection:
- Pressed or Crimped
- Soldered Copper or Tin-Coated Copper
- Bolt Attachment (With detachable bolt-heads) for universal connectors
- Welded (Oxyacetalene (Gas), Point/Spot or Thermite);
Types of Connection
Pressed or Crimped - Standard method of connecting a cable lug to a cable, Carried out via manual or hydraulic pressing.
Pressed Calipers - (using hydraulic or manual pressing) establishes a connection using at least two clips to ensure a stable contact with the cable. This method is viable for single wired cables, but requires the calipers to be selected specific to the size of the cable and thorough removal of the insulation and antioxidant film from the cable.
Welded Connection — Attachment is achieved by welding the lug and cable together using a tin based flux. However, due to technological advancements allowing for easier methods of attachment; this type of connection is rarely used.
Oxyacetelyne Welding - This method ensures a reliable connection between the core and the lug, however this method requires bulky equipment and has to be carried according to strict rules and safety precautions.
Point/Spot Welding - Another popular method of establishing a connection between cable and lug. This method provides a durable and stable contact without the need for soldering. Although the principles behind this method are simple, the quality is dependent on the source of electrical energy used.
Thermite Welding - A simple method of making a connection that does not require any overly complicated equipment to perform. However the equipment used has to be stored according to safety regulations.
Bolt/Screw Attachment — The lug is mechanically attached to the cable using a bolt or screw.
When selecting the appropriate type of termination and method of connection; some important factors must be taken into account. These can be identified by the specialist carrying out the installation, depending on the connecting materials (Copper, Aluminium or a combination of both) and the intensity of electrical charge in the system or circuit.
Utility of Cable Lugs:
Cable lugs are ubiquitous in industrial settings.
Copper cores, with cross sections of 2,500 to 240 мм sq. and Aluminium cores with cross sections of 16 мм sq. are always crimped in order to give corrosion resistant properties and ensure a reliable connection.
The presence of cable lugs at Inlets, protective screens and grounding wires is essential.
Cable lugs can be found in a variety of household appliances, including: Washing machines, microwaves, air conditioning and other electrical appliances. Most commonly, these types of lugs are either calibrated to the device being used or contain calipers for attachment. The cables and lugs are usually connected via crimping or welding/soldering.