What are D10 cables currently used for?

Cable lugs: which one is the right one for what

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Wide range: the choice of the right cable lug

There is a large selection of cable lugs available for a wide variety of electrical applications. Making the right choice here can be more difficult than you think. But the choice of a suitable cable lug is of decisive importance for a clean and safe crimping result.

In this overview, we take a closer look at the most common cable lugs for copper conductors and explain what you need to consider when making your selection so that your connection is really safe and durable.

Cable lugs for copper conductors, which are connected to the conductor by so-called cold forming, are among the most common connectors in electrical engineering.

They can be roughly divided into three groups:

Cable and cable lug: a perfect pair

The choice of the right cable lug also depends on the conductor class that is to be processed. For example, the following cable lug types are suitable for cables according to DIN EN 60228:

  • Class 1, 2, 5 and 6 conductors: compression cable lugs according to DIN 46235
  • Class 2 conductors: tubular cable lugs, normal design
  • Class 2, 5 and 6 conductors: Crimp cable lugs according to DIN 46234

For the safe pressing of conductors with DIN compression cable lugs, the standard recommends pressing tools with code number inserts according to DIN 48083 part 4. In the case of tubular cable lugs, the specifications of the respective manufacturer must be observed.

The crimp cable lugs according to DIN 46234 are processed with a mandrel crimping.

Quality and durability: put to the test
Standards also apply to the electrical and mechanical properties of cable lugs. In this case, it is the international standard IEC 61238 Part 1. It specifies the tests that an electrical connection must fulfill for long-term safe operation in the intended application. To do this, the electrical connections have to undergo various tests. In addition to a mechanical tensile test, an electrical durability test is also required. In this a test cycle simulates practical use.

The connection is heated 1000 times to approx. 120 ° C by means of electricity in order to bring about artificial aging. The transition resistance is checked at regular intervals between these tests. In addition, six high-current tests are carried out in which the conductor is heated to approx. 250 ° C by a short circuit in one second. This high-current test is mandatory if the connector is to be tested as being short-circuit proof. The Klauke connection material also passed this test. The press connection has passed the test when the contact resistance has remained constant throughout.

Manufacturers are responsible for guaranteeing the security of their connections. With these additional tests, you can be sure that our connecting material meets the highest demands. In addition, a large part of our materials has also been tested and certified by the UL. This is particularly interesting if, for example, control cabinets are to be delivered to North America at a later date.

In addition to the normative requirements, we also place further requirements on the quality of our products. Klauke cable lugs are annealed in an additional production step. This enables us to reduce hardening and tension in the material and reduce the risk of breakage during pressing.

The quality of cable lugs can already be seen from the optical characteristics. A burr-free production and a uniformly flat flange indicate a high-quality product - as well as a clean end machining of the pipe section.

More information about the right cable lug:

  • Compression cable lugs according to DIN 46235for the press connection of solid, stranded, fine and extra fine stranded copper conductors
  • Standard tubular cable lugsMade of electrolytic copper (EN 13600) mainly for multi-wire copper conductors
  • Crimp cable lugs according to DIN 46234for the press connection of stranded, fine-stranded and extra-fine stranded copper conductors
  • The selection of the right cable lug depends crucially on the conductor class to be processed and the customer requirements.
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