Broad range: selecting the correct cable lug

A broad range of cable lugs is available for the most diverse applications in the electrical sector. Making the right choice can be more difficult than you think. However, selecting the correct cable lug is the key to a clean and reliable crimping result. This overview shows the most common cable lugs for copper conductors. We will explain what to bear in mind as you make your choice to ensure a highly reliable and durable connection.

Cable lugs for copper connectors, which are connected to the conductor by means of so-called cold deformation, are among the most common connectors in electrotechnology.

They can be generally divided into three groups: 

Cable and cable lug: a perfect pair

Selecting the correct cable lug also depends on the conductor class to be processed. For example, we offer the following cable lug types for cables to DIN EN 60228:

  • Class 1, 2, 5 and 6 conductors: Compression cable lugs to DIN 46235
  • Class 2 conductors: Tubular cable lugs standard type
  • Class 2, 5 and 6 conductors: Solderless terminals to DIN 46234

To ensure the reliable crimping of conductors with DIN compression cable lugs, the standard recommends crimping tools with die codes to DIN 48083 Part 4. In the case of tubular cable lugs, the specifications of the manufacturer concerned must be observed. 

Solderless terminals to DIN 46234 are processed by an indent crimp.

Quality and durability: on the test bench

The electrical and mechanical properties of cable lugs also have to comply with standards. In this case, IEC 61238 Part 1. This international standard specifies the tests an electrical connection has to pass for continuous, reliable operation in the intended application.

The electrical connections must therefore undergo various tests. In addition to a mechanical tensile test, an electrical durability test is also specified. A test cycle simulates practical application. The connection is heated by electricity 1000 times to approx. 120 °C to induce artificial ageing. Between these tests, the tran-sition resistance is checked at regular intervals. Six high-current tests, during which the conductor is heated to approx. 250°C in one second via a short circuit, are also carried out. This high-current test is specified whenever the connector has to be certified as short-circuit resistant. Klauke connectors have passed this test too. The crimped connection has passed the test if the transition resistance has remained constant through-out.

Manufacturers are responsible for guaranteeing the reliability of their connections. These additional tests are your assurance that our connectors satisfy the highest demands. In addition, many of our connectors have also been tested and certified by the UL (Un-derwriter's Laboratories). This is particularly useful when control cabinets are to be supplied to North America, for example.

However, we set requirements for the quality of our products beyond the normative standards. Klauke cable lugs are annealed in an additional production step. This allows us to reduce the hardening and stresses in the connector and reduce the risk of breakage during the crimping process.

The quality of cable lugs is evident even from optical features. Burr-free production and a consistently flat palm are signs of a high-quality product – likewise clean final machining of the tube section.