One of the electrical industry's challenging responsibilities is creating a robust terminal or a junction between a cable and an electrical system. These junction points maintain the integrity and operability of an electrical system. A minor fault in them can cause tremendous damage. Hence, cable lugs get used to create proper connectivity even if the cables are in tension indoors and outdoors.

Design features of copper cable lugs

Made of copper and aluminum, the design features of the cable lugs ensure the connectivity and safety of the cable terminals and the electrical system. In most cases, copper cable lugs are chosen for better connectivity, strength and durability in the terminal junctions.

A cable lug design has a barrel and a palm. The entire structure is properly shaped using copper, the best metal conductor within the price range. The barrel section has a perfect lumen size that matches the specific diameter of the copper cables (size ranges from 1.5 to 1000 sq. mm in diameter) used in the modern electrical industry. It means the barrel part is made hollow to easily accommodate the end point or terminal of a copper cable.

The palm section is a flat semicircular or square projection above the barrel with a hole. This hole connects with a junction in an electrical system. When a cable terminal is inserted and crimped, the barrel will not leave space inside. Likewise, the palm section will provide ample strength to hold the junction in its place.

How does a copper cable work?

Now that we know the design and structure of a copper cable lug, we can easily understand how it works. A copper cable lug gets chosen according to the specifications, such as the cable diameter and the features of the junction of an electrical system.

 

A cable is then inserted into the barrel section of a cable lug. It is then crimped without leaving space inside to avoid electrical malfunctions. Once the terminal is ready, the palm is attached to the electrical system junction as per suitability or the directions given in the product specifications. Generally, the palm of a cable lug is screwed tightly with the electrical system. A spring clip or bolt is also used to connect a cable lug to an electrical system.

 

Based on the design specifications, there can be more than one palm hole in each copper cable lug. Match an electrical system's termination or connection features to get a vital junction

Things to consider

Generally, copper is the prime choice for cable lugs to create a vital junction due to its exceptional strength and malleable properties. Based on the cable properties and electrical system junction features, a cable lug is chosen to create a better connection that will stand the test of time.

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