Types of Lugs

Types of Lugs


A cable lug is a component of an electrical device that connects the cable to the device terminals. It simplifies the assembly of personnel, maintenance, and repair processes. The cable lug or connector is used when a permanent connection is required but a direct one is inconvenient or impossible to achieve.

Lugs are made of high-grade electrolytic copper (ETP Grade) and available in a range of diameters and mounting holes, with wire sizes ranging from #8AWG to 1000MCM. The terminals are CSA & UL approved, and they have corrosion-resistant tin plating.


Classification of  Various Types of Lugs

Copper Lugs:

Copper lugs are ideal in large gauge applications for power draw or grounding. The wire can be soldered or crimped to each copper lug. One end of the copper lug takes the cable by soldering, welding, or crimping, depending on the type of lug. The other end of the copper lug is secured to a matching termination or connection point by a bolt, screw, or spring clip.

Types of Lugs


AXIS manufactures cable lugs in a range of styles. AXIS Copper Cable Lugs offers users terminals that are designed and built for easy installation and long-term dependability. AXIS Copper Lugs are made of high-grade ETP Copper material and tinned for corrosion protection. Excellent for any outdoor application or in a marine environment.

With cable sizes ranging from 1.5 sq., mm to 1000 sq. mm, AXIS Copper Lugs are dependable with rapid termination methods for interconnecting heavy gauge power cables to bus bars, relays, batteries, solar power inverters, power cables, grounding devices, and more, with increased efficiency, safety, and reduced costs.


Aluminum Lugs

Aluminium lugs are manufactured from the solid aluminium rod using high conductivity (99.6%pure) aluminium. They are forged from solid material and are suitable for outdoor use as the palm ends are sealed. Aluminium Lugs are supplied with jointing compounds in the barrels and are sealed with an end cap. Standard sizes are listed, but others can be punched to the requirements. Crimping takes place with hex dies and usual aluminium cable preparation.

Copper lugs are better in many numerous ways. However, Copper lugs are a bit more expensive than aluminium lugs. Due to its low price, aluminium wires and lugs are in almost every wiring system. Aluminium lugs related innovations are being made, making them as safe and convenient as copper lugs.

Aluminium lugs are then tinned with a middle layer of copper coating for corrosion protection and are barrel entry chamfered at the end to provide easy insertion into a barrel.

The inner barrel of the lug has an AntiOxide compound, which reduces oxide formation caused inside and helps to get a better connection after crimping the lug with the conductor. However, UL listed aluminium lugs come with AL9CU marking, which is rated for a 90o C system and indicates dual rated lugs with either copper or aluminium conductor.


Bimetallic Lugs:

AXIS based bimetallic lugs made of Friction welding establish the highest quality connection between the copper palm and the Aluminum barrel.

Bimetallic Lugs are used in Solar Plants to connect aluminium conductors to copper busbars in a range of electrical applications such as control panels, switchgear, and combiner boxes.


Bimetallic lugs

The Aluminum barrel is friction welded to the copper palm, achieving the best possible transition between barrel & palm.

As a result, the aluminium conductors touch the aluminium barrels, and the copper busbar touches the copper palm. To prevent oxidation lug barrel is filled with contact lubricant to improve contact properties, thus enabling smooth electrical connection.

We manufacture a wide range of Bi-metallic and other types of lugs, connectors and specialised items to meet specific customer needs. Other combinations, for example, can be made if the buyer requires them:

1-Bi-metallic lugs - Aluminium barrel with copper palm (with single, double, or four holes)

2-Bi-metallic lugs with copper washer (Aluminium lug with copper washer)

3-Bi-metallic lugs reverse type (Copper barrel with aluminium palm)

4-Bi-metallic connectors – Straight type (for the same cross-section of Al & Cu cables)

5-Bi-metallic connectors – Reducing type (for different cross-sections of Al & Cu cables)

6-Bi-metallic connectors - Pin type (Aluminium barrel with solid copper pin)



Crimping Lugs:

Crimping is the process of deforming one or both of two pieces of metal or similar material to hold the other in place. The bend or deformity is called a crimp.

Crimping lugs are connectors that connect cables, surfaces, and machinery. The clamps connecting wires to an automotive battery, and the ends of battery jumper cables, are examples of crimping lugs.

These types of lugs are used in automobile wire systems, electrical boxes, machinery, household appliances, electronics, and other durable goods. For electrical applications, they are insulated with rubber or plastic. They prevent accidental energy transfers to people or neighbouring electrical components other types do not require insulation due to lug placement or a lack of voltage.


Mechanical Lugs:

Mechanical connector technology, which is the Best-Fit method for attaching cable conductors, uses cutting-edge technology such as shear-off bolted connectors, in which the bolt head shears off at a predetermined torque and is thus independent of the installers knowledge. These mechanical connectors or shear bolt connectors are of certain alloys.

Mechanical connectors are of sleeve and lug bodies, which are of a high-tensile aluminium alloy. The interior surfaces of the connectors are grooved. Sleeves are suitable for underground use. Lugs are available in several palm hole sizes and can suit both outside and inside. Mechanical connectors are available in low voltage, medium voltage, and high voltage versions.


Compression Lugs VS Mechanical Lugs:


Features & Characteristics of Various Types of Lugs:

There is a mechanical pull-out test as well as an electrical durability test.

For entering the wire barrel there are either shock-proof portions of the entry is bell-mouthed. This allows conductors to be inserted swiftly.

The cable lugs are subjected to high current tests at temperatures of 250°C, great-quality materials provide optimal conductivity, high loading capacity, and increased safety.

Flat contact surfaces and an inside chamfer make for a simple and secure connection due to the simple press markings processing. Copper lugs are annealed to a specific temperature to improve material properties and for better crimping.

All copper items are electro-tinned to BS specifications, which prevents corrosion and oxidation, terminals are insulated with PVC for outstanding dielectric strength and support.

Copper tube dimensions are customised to fit a specific of cable, ensuring complete electrical conductivity and mechanical strength to withstand vibration and pull-off.


Application of  Different Types of Lugs:

Cable lugs make it simple to install, repair, and maintain electrical devices and cables. They link two wires together or connect more than two cables. They also connect fuse sockets, load switches, and electrical equipment.

In the industry, cable lugs of various sizes, forms, materials, and configurations are employed. Insulated lugs with pin terminals, blade terminals, hook terminals, fork terminals, and ring terminals are in the wire, automation, control panel, and instrumentation industries. Copper ring-type lugs are often for many connecting reasons. Copper cable lugs connect several of the gadgets with cables.

Butt and parallel connectors are other forms of lug they join and terminate two cables. PVC insulated, butt type, heat shrinkable, and closed-end type are some of the most commonly used butt and parallel connections. They are employed in most industries where cables are routinely used to connect equipment. It comes in a variety of sizes, shapes, and materials. Depending on the type of cable used to connect one item to another, copper cable lugs are utilised as butt and parallel connectors.

In the wire and electrical sector, lugs have indispensable usage. Before employing it in a heavy-duty application, it should be tested for strength. The strength and design of lugs are crucial t in many applications. Choose lugs based on their intended use.

Often used to connect distribution boxes and transformers to cables, Terminations in MV. On the Bus Bar, there are LV connections, they terminate all sizes of cables and electrical switching equipment, in environments where vibration is a factor.

Transformers, motors, generators, batteries, distribution boards, and other industrial segments use it. Usually in control panel cubicles to terminate flexible control wires to metres, connectors, and terminal blocks.


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