The electrical power generated at the power station goes through several cables, devices, and systems, before reaching its destination. For the safest and most efficient power transfer, a reliable electrical system is required. Compression Cable Lugs and Connectors play an important role in ensuring this safety, efficiency & reliability. In this article, we will discuss compression cable lugs & connectors, their applications, and their installation procedures.

What are Compression Cable Lugs & Connectors and their applications?

Compression cable lugs and connectors are constructed out of electrolytic copper or aluminum depending on the application. Cable lugs mechanical parts used for connecting electrical cables to other electrical appliances, cables, and surfaces. They are designed to ensure smooth, fast, and efficient connections.

The Lug has one hollow cylindrical end called a barrel where the cable is inserted. After insertion, the cylindrical end of the lug is crimped using a crimping tool to secure the cable within the lug. The other end is a flat surface called a Palm. The palm usually has a hole to help connect the Lug to the machine, surface, or busbar by using a suitably sized fastener. At Axis, we provide termination solutions to hundreds of clients across the world – our solutions include UL Listed Compression Cable Lugs, crimping tools, and dies in numerous designs, materials, and capacities. Click here to view our catalogue

The design of the compression cable connector consists of one hollow cylindrical tube where the two cables will be inserted from either end. The connector has a cable stop facility at the center ensuring equal lengths of the cable will be inserted from both sides.

The compression connectors are used for forming a continuous path for electrical current through cables & wires by joining them together. Both the cables are secured inside the connector by crimping process using crimping tools and dies. At Axis, we provide termination solutions to hundreds of clients across the world – our solutions include UL Listed Compression Connectors, crimping tools, and dies in numerous designs, materials, and capacities. Click here to view our catalogue

The installation procedure of the cable lug

Step 1: Removal of the Cable Insulation

Remove the insulation on the cable with the required depth of the barrel of the lug with a suitable allowance (3 to 5 mm) and make sure that the correct cable is being connected with the lug. It can be done by checking the markings on the cable or from the labels and then matching it with the cross-section area which is marked on the Lug surface. Note: For the 3-phase connection, the required color coding of the lug or connector should also be kept in mind.

Step 2: Insert the cable into the barrel of the lug

If any extra oxides are present on the cable strands, please remove them using a cable brush to ensure proper connections. Now, insert the cable into the barrel of the lug. The orientation of the lug palm (flat outer part of the lug) should be kept in such a direction that it gets easier for the technician to connect the cable where it is to be connected.

Step 3: Create a strong joint using the right crimping tools and dies

To ensure a secure connection between cable and lug, please ensure that you use the correct crimping tool and die as stated by the lug manufacturer. Their correct selection plays an important role in ensuring the mechanical strength and electrical continuity of the joint. The correct size of the fixing bolt is important to create a strong, clean, and efficient electrical connection with the connected busbar.

Compression cable lugs & connectors play an essential role in electrical systems. The quality of material, the design of the lug, the tools & dies used while crimping plays an important role in defining the life and sturdiness of the joint. Incorrect tools & dies will lead to improper cable crimps which will cause increased joint temperature or fire, resulting in damage to buildings, systems, and even human life in the worst case.

Please contact us for the best quality Cable Lugs and Connectors.