Electrical connector#Blade connector

Cable lugs ensure that the electrical installation technology is a simplified electrical contacting of the conductors of cables or single wires ( stranded wire ) with screws ( loop, fork) or Insert ( flat connector).

For fastening of cables in terminals in contrast, are often necessary ferrules. Massive Head can be screwed directly by bending the wire into a loop. For mounting from stranded wire is also crimping rings, in which the strand is inserted annular. Also suitable for solder lugs are not referred to as terminals.

As an eyelet or fork terminals enable clamping contact formed of electrically conductive components with a screw, which is connected to this component and clamping contacts one or more terminals.

Species

Essentially three types of cable lugs can be distinguished. In addition to the types with bolt sleeve are:

Crimpkabelschuhe

In Crimpkabelschuhen the conductor receiving is formed by a plate which is laterally curved upwards. When crimping, this area along with conductor end in a crimping tool or machine is inserted. This bends the sheet-metal tabs inward and downward on the conductor end, thus resulting in a kidney-shaped cross-section. Often other two metal tabs are also available at the site of the end of the conductor insulation, so that in the same way a strain relief and bend protection can make there. Both crimp operations may either separately ( Crimping tool with adjacent dies ) or can be run simultaneously. In the Crimp dies for both crimps are arranged one behind the other.

For insulated Crimpkabelschuhen this area is under a insulating sleeve, through which affects the pressing force. When crimping at the same time the extended end of the insulating sleeve is pressed to the isolated area of the pipe so as to form a kink protection. The insulating sleeve insulated terminals to the cross section has a distinctive color:

• Red for cross-sections from 0.5 to 1.0 mm2
• Blue for cross-sections from 1.5 to 2.5 mm2
• Yellow for cross sections of about 2.5 to 6 mm2

Compression cable lugs

Compression cable lugs have a thicker, often closed, tubular conductor recording, which is deformed with a crimping pliers, so that a force - and form fit with the ladder. There are different pressing tongs for certain cross-sectional areas, since the cross section of the sleeve must match that of the conductor and various forms ( hexagonal cross-section or one or two blunt prongs that push the sleeve in the center cone shape on the wire).

A special design of cable lug in combination of a plug set the standard, especially in the auto electric flat connector in combination with a cable lug dar. This inexpensive design comes in various sizes both male and female before and allows for servicing easy separation of an electrical connection. This design is also known colloquially under the registered trade name or as Faston Faston connector.

Compression cable lugs are used for copper conductors, but especially for aluminum conductors ( large cross sections in power grids ).

Assembly

One with a cable lug to the cable end Instant verse is first stripped in its end. The stripping length and usable conductor cross-sections are specified for each cable lug from the manufacturer. Then, a cable lug is fitted onto the stripped end portion. Crimp and Compression cable lugs are then deformed using a special crimping pliers or a press with a corresponding die. In this way, a power circuit, and an electrically conductive connection between the cable and the cable lug is guaranteed.

Crimping pliers often leave a mark on the cable shoe, they have to die in an engraving. This is used for quality control.

A cable shoe in a crimping tool during the crimping

A finished crimped cable lug is quetschter labeling, to the pliers with appropriate engraving

Two cable lugs; before (left) and after crimping (right)

Solder joints are rarely used because properly performed, crimp and press connections are much more reliable.

Tools

Crimp and crimping pliers are special tools for small quantities. You and also mechanized solutions have one or more dies for processing one or more cross-sections of a particular cable lug type. Often the jaws have a device which only releases the lug back when the required pressing pressure has been applied.

In production, crimp and compression cable lugs are ( manually inserted or fully automated including Abisolation ) with mounted presses. For mobile use when working on the power grid, there are motorized hydraulic presses in order to compress large cross-sections on the spot.