CABLE LUGS MANUFACTURING (COPPER & ALUMINIUM)

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Cable lugs are the devices used for connecting cable and wire conductors in electrical installations and equipment. These are used when permanent, direct fastening methods are not feasible or necessary. In general, lugs are fixed to cables and wires by inserting the conductor/s into the barrel (tube) of the device and then barrel is crimped, soldered or welded onto the conductor for secure mechanical and electrical joint. The connection end of the lug is then fastened to connection point by means of a bolt, screw, or spring clip. Numerous sizes, configurations and material types are available to suit particular applications.

Connector end of lug is typically chosen for its compatibility to the terminal type. Fork or U-shaped lugs are used for screw terminals; closed-ring or O-type lugs are used for bolt-on applications; and pin lugs are used for press-on terminals. A cable lug also serves as a cable-size reducer, thereby allowing thick cables to be attached to a connector with a smaller diameter.

Cable lugs are devices used for connecting cables to electrical appliances, other cables, surfaces, or mechanisms. The clamps that connect wires to an automotive battery are a common example of a cable lug, as are the ends of battery jumper cables. Designed to be easily installed and removed for repairs or maintenance, cable lugs area generally used when permanent, direct-fastening methods are not feasible or necessary.

The words “cable” and “wire” are sometimes mistakenly interchanged. Cables are made from multiple wire strands, while wires consist of a single strand. Both cables and wires may be used with cable lugs of a suitable type.

One end of a cable lug is typically used for connecting a cable, which could be soldered, welded, or crimped depending on the type. The connection end of the lug is then fastened to a matching terminal or connection point by means of a bolt, screw, or spring clip. Numerous sizes, configurations, and material types typically are available to suit particular applications, but metal is the predominate material used. A cable lug is sometimes called a “cable connector” or “cable anchor,” depending on industry jargon and application.

The connector end of a cable lug is typically chosen for its compatibility to the terminal type or anchoring method. Fork or U-shaped lugs are used for screw terminals; closed-ring or O-type lugs are used for bolt-on applications; and pin or spade lugs are used for press-on pin or blade terminals. A cable lug also serves as a cable-size reducer, thereby allowing thick cables to be attached to a connector with a smaller diameter.

Lug is a connecting device with barrel accommodating respective conductor size of electrical cable and which has a fixing arrangement of termination by means of a bolt fixing or pin-insertion in tunnel type terminal blocks and screwing.

Cable lugs, also referred to as Cable terminal ends or cable shoes are electrical supplies utilized to securely connect or terminate cables to electrical devices, power or control panels, junction boxes, equipments and machineries. These lugs are often used to join power cables together as well. Cable Lugs intended to ensure the safety of both the appliances and human beings. These lugs can be uniquely engineered according to the client’s preferences and requirements.

The functionality of a cable lug is one of the most safe and common method of cable termination. It is designed in a way that cable termination and removal for maintenance or repair is very simple, thus a cable lug is broadly used instead of direct fastening methods. It is also utilized by almost electrical equipment even in manufacturing of tires for vehicles, drums and many others.

The various types of lugs consist of terminal lugs, tube lugs, fork lugs, bi metallic lugs and aluminum tubular lugs. The option for the material used in cable lugs depends on the type of the cable. Electrical cable lugs can be used on automobiles as the role of lugs for efficient performance of the machines is highly indispensable as well as in electrical boxes, transformers and generator machines.

Copper lugs are utilized widely for numerous functionality; they are often used to decrease the diameter of a thick cable for it to be able to attach the cable to the other end that are of small diameters. Copper wires used in speakers are commonly made with spade lugs that are gold plated on top which give full protection to the speakers and keep them protected for maximum performance and durability. Also, there are terminal lugs and compression cable lugs which are made with PVC sleeves for protection to avoid any kind of electrical shocks and shortages. When you see the various types of electrical cable lugs, you are definitely going to find lugs which have sleeves that are made of reinforced metals and others made of battery cable lugs. The function of having metal reinforcement is that it helps the cable lugs to have perfect grip and have smooth travel of current through the conductor, thus helping it be safe and protected. In some cases where there is more vibration, lugs act as terminators for the elec
trical cables from current connection.

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Description

INTRODUCTION
TYPES OF LUGS:
USES AND APPLICATION
TYPE OF TERMINALS APPLICATION
FIELD OF APPLICATIONS
B.I.S. SPECIFICATION
MARKET SURVEY
MAJOR COMPANIES
SPECIFICATIONS OF CABLE LUGS
MANUFACTURERS/SUPPLIERS OF CABLE LUG
PROCESS FLOW CHART
FABRICATION PROCESS OF LUG
QUALITY CONTROL
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OIF PLANT AND EQUIPMENTS
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
MANPOWER
UTILITIES
SWOL ANALYSIS
PLANT LAYOUT
ORGANIZATION CHART
IMPLEMENTATION SCHEDULE

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

1.75 MT/Day

Land & Building

(2600 sq.ft.)

Plant & Machinery

US$ 37142

Rate of Return

65%

Break Even Point

26%