Cable lugs, also known as Cable shoes or Cable Terminal ends are Electrical Accessories used for securely connecting or terminating power cables to electrical apparatus, junction boxes, power or control panels, machineries or equipments. They are also used for joining power cables together.
Power cables carry electric current to electrical apparatus, junction boxes, power or control panels, machineries or equipments. Depending on the size of the cable, current carrying capacity varies from a few amps (electric current is rated in amperes) to thousands of amps. Proper connection or termination of these power cables is essential as improper connection may lead to short circuit or leakage and may in turn lead to costly damage to man and machinery. A proper termination of the power cable is done by securely joining the leading end (after removing insulation) of power cable to the bus bar inside the junction box or panel or onto the input point of the equipment.
Usage of lugs is one of the most common and safe way of power cable termination. They are designed in such a way that cable termination as well as removal for repair or maintenance is very easy, hence they are widely used in place of direct fastening methods.
A typical cable lug has a tubular structure with one end flattened with stud hole for securing the end using bolt or screw to bus bar inside the junction box or panel or onto the input point of the equipment. The spliced end of power cable is inserted into the tubular end of lug. This could then be crimped or soldered or welded for secure connection. Once securely joined this way, cable lug acts as a leading end to the power cable.
These Lugs are usually made of Copper or Aluminum, same as the material uses for power cables. The lugs are of various sizes and are available in different current carrying and voltage handling capacity to suit each power cable and application.
Lugs are produced in power press by forging and die cutting suitable copper or aluminum tubes. Accurately designed presses, tools and dies are used in production of good quality lugs. To produce a Copper Cable lug, copper tubes of suitable size is drawn. The tubes are annealed to remove material hardness. The tubes are cut into predesigned length and then forged and cut using power press. The finished lugs are tin plated for avoiding oxidation and lasting performance.
Exar lugs are known for its high quality, accuracy and performance. Exar uses the state of the art technology and best quality equipments to produce the them. We are equipped with the most modern tool room which helps us design and develop with precision for all application. Exar has a large range of lugs to suit most of the application. Our design and production methodology ensures defect free finish.