Quality and resistance: on the test bench
Standards also apply to the electrical and mechanical properties of cable lugs. The international standard IEC 61238-1 part 1 applies in this particular instance. It specifies the tests that an electrical connection needs to fulfil in order to ensure long-term safe operation for its intended use. The electrical connections must undergo different tests for this purpose. This involves an electrical durability test alongside a mechanical tension test. A test cycle simulates a practical application in this test.
Electricity is used to heat up the connection 1000 times to approx. 120 °C in order to bring about artificial ageing. The contact resistance is reviewed at regular intervals in between the tests. Six high current tests are also carried out where the conductor is heated up to approx. 250°C in one second thanks to a short circuit. This high current test is required if the connector is due to be tested to check it is short-circuit protected. The Klauke connecting material has also passed this test. The crimping connection passes the test if the contact resistance remained constant throughout.
Manufacturers are responsible for being able to guarantee the safety of their connections. With these additional tests that are carried out, you can rest assured that our connecting material satisfies the highest demands. In addition, a significant amount of our materials are UL-tested and certified. This is particularly useful when control cabinets are to be supplied to North America, for example.
However, we also place additional requirements on the quality of our products that go beyond these standard requirements. Cable lugs made by Klauke are annealed as part of an additional manufacturing stage. This means we can reduce any hardening and tension in the material, as well as reduce the risk of breaking during crimping.
The quality of our cable lugs is already evident from their visual characteristics. Burr-free production and a consistently flat palm are signs of a high-quality product – likewise clean final machining of the tube section.