Insulated and Uninsulated Cable Lugs
In general, there are three types of cable lugs: compression cable lugs, tubular cable lugs and crimping cable lugs.
In the illustration above, you can see the compression cable lug on the far left, the tubular cable lug in the middle, and the crimp cable lug on the far right.
DIN 46235 compression cable lug
DIN compression cable lug narrow (left) and wide (right)
The standard (DIN 46235) specifies the dimensions for all manufacturers of DIN compression cable lugs.
Features compression cable lug:
- A compression cable lug is larger and longer than a commercial tubular cable lug.
- Commercially available tube cable lugs have different tube diameters than DIN compression cable lugs
- The markings on the tube (bar code) of the DIN compression cable lug specify the number and width of the crimps (there are wide and narrow crimps, hence 2 bar lines parallel to each other)
- On the flange of the DIN compression cable lug, in addition to the embossing for the cross-section, the hole diameter and the manufacturer, there is also an embossed identification number. This allows a suitable tool insert (press insert) to be assigned. The crimping dies for DIN crimping cable lugs also have a code number which leaves a control imprint on the cable lug after crimping. (In the example picture above > left the "20").
- For DIN compression cable lugs, the 46235 standard recommends the use of hexagonal compression inserts.
- According to the NORM, these cable lugs may be used for single, multiple, fine and ultra-fine stranded copper cables. Their field of application is mainly in the areas of power supply companies.
We offer compression cable lugs with cross sections from 6 to 1000 QMM.
Tubular cable lugs
|Commercially available tubular cable lug||compression cable lugs are usually longer than tubular cable lugs||Tubular cable lugs (left) have different tube dimensions than compression cable lugs (right)|
Features of tubular cable lug:
- The commercial tubular cable lug has a shorter tube compared to the DIN compression cable lug.
- Tubular cable lugs have different dimensions in the area of inner tube diameter and connecting flange
- A tubular cable lug has no specifications (bar code) with regard to the number of crimps or codes for the tools to be used.
- For a tubular cable lug there are various possibilities for crimping: Mandrel crimping, hexagonal crimping, WM crimping. Care must be taken to ensure that the correct size is used for the appropriate cross-section. Over- or under-pressing of the tubular cable lug can lead to increased transition resistances and can then result in temperature increases.
The application area for commercial tubular cable lugs is mainly in the field of distribution and post-metering. We offer tubular cable lugs in cross sections from 0.5 to 400 QMM.
Please note: some manufacturers offer their own series of tubular cable lugs. These are made from a thinner tube and must therefore also be crimped with the manufacturer's own tool. Tubular cable lugs from us or other manufacturers cannot be crimped using the manufacturer's tool. If you are not sure before buying, please contact us. We will be pleased to advise you.
Crimp cable lug according to DIN 46234
|Crimp cable lug||Crimp cable lug crimped with mandrel crimping|
Features crimp cable lugs:
- Crimp cable lugs are made from a bent sheet of metal and then soldered to close the formed tube
- Crimping cable lugs have a short design and are open to the front
- Crimp terminals have a round connection flange
We offer crimp cable lugs in cross sections from 0.5 to 240 QMM. For processing, it is recommended to use a "mandrel crimping" here.
The application areas of these cable lugs are mainly in the fields of: Distribution board construction, vehicle construction and switchgear construction.
Possible crimping of cable lugs
The crimping of cable lugs not only has an influence on the service life of the connection. Over- or under-pressing of a cable lug can also lead to increased contact resistances. This can lead to temperature increases.
The advantage of "hexagonal crimping" is the centric application of force during crimping. It is applied evenly from all sides and thus acts on a large contact area. The individual strands of the conductor are uniformly deformed as a whole without damage.
Mandrel crimping" and notching give the best results for fine and superfine stranded conductors.
The "WM" crimping is basically a double mandrel crimping and takes its name from its shape, which is similar to a W and M. This form of crimping allows suitable cable lugs to be crimped onto stranded, compacted and fine-stranded conductors.