Cable Lug Manufacturer - VIOX Electric Factory
VIOX Electric is a leading cable lug manufacturer based in China, specializing in high-quality electrical connection solutions for over 15 years. As a professional cable lug factory, we produce comprehensive ranges of copper cable lugs, aluminum cable lugs, and bimetallic cable lugs that meet international standards including CSA, CE, and ISO certifications.
Our cable lug manufacturing facility delivers factory-direct pricing without compromising quality, making us the preferred choice for electrical contractors, industrial facilities, and infrastructure projects worldwide. From standard cable lug configurations to custom solutions, VIOX Electric combines advanced manufacturing technology with rigorous quality control to ensure every cable lug meets the highest performance standards.
Certifikováno
VIOX Copper Cable Lug
VIOX Bimetallic Cable Lug
VIOX Aluminium Cable Lug
Stručná vlastní nominace: Proč si vybrat VIOX Electric?
At VIOX Electric, we’ve established ourselves as a leading manufacturer of high-performance cable lugs and electrical connection solutions for over 15 years. Our commitment to quality and innovation has made us the preferred choice for electrical contractors, industrial facilities, and infrastructure projects worldwide.
- Engineered for Excellence: Every cable lug undergoes rigorous quality control and testing
- Globální dodržování předpisů: Our products meet IEC, UL, CSA, and other international standards
- Exceptional Conductivity: Premium-grade materials ensure minimal resistance and power loss
- Extensive Selection: One of the industry’s most comprehensive ranges of sizes and configurations
- Technická podpora: Our engineering team provides expert guidance for your specific application
- Konkurenční ceny: Factory-direct pricing without compromising on quality
VIOX FULL RANGE CABLE LUG
Our comprehensive cable lug portfolio is engineered to meet virtually every electrical connection requirement across industries.
- Copper cable lugs
- Tinned copper lugs
- Aluminum lugs
- Bimetallic lugs
- Welding cable lugs
- Tubular lugs
- Copper tube terminals
- Cable lug pin type
- Cable jointing
- Pre insulated lugs
- Pre insulated connector
- Mechanical lug
- Mechanical connector
- Split bolt connector
- C connector
- Copper cable link
- Aluminum cable link
VIOX Cable Lug SIZE CHART
| MODEL | DIMENSION | VAL THICKNESS | |||||||
|---|---|---|---|---|---|---|---|---|---|
| D±0.2 | D±0.2 | G±0.3 | L±1.5 | L1±1 | W±1 | Φ±0.5 | |||
| JG10-6 | 8 | 5.6 | 2.5 | 38 | 21 | 12 | 6.5 | 1.2 | |
| JG10-8 | 8 | 5.6 | 2.3 | 38 | 21 | 13 | 8.5 | 1.2 | |
| JG16-6 | 9 | 6.4 | 3.0 | 40 | 23 | 13 | 6.5 | 1.3 | |
| JG16-8 | 9 | 6.4 | 3.0 | 40 | 23 | 13 | 8.5 | 1.3 | |
| JG25-6 | 10 | 7.3 | 2.8 | 45 | 25 | 14 | 6.5 | 1.35 | |
| JG25-8 | 10 | 7.3 | 2.8 | 45 | 25 | 14 | 8.5 | 1.35 | |
| JG35-8 | 11 | 8.2 | 3.0 | 50 | 28 | 15 | 8.5 | 1.4 | |
| JG35-10 | 11 | 8.2 | 3.0 | 50 | 28 | 15 | 10.5 | 1.4 | |
| JG50-8 | 13 | 10 | 3.0 | 54 | 30 | 19 | 8.5 | 1.5 | |
| JG50-10 | 13 | 10 | 3.0 | 54 | 30 | 19 | 10.5 | 1.5 | |
| JG70-8 | 16 | 12 | 3.7 | 61 | 33 | 23 | 8.5 | 1.5 | |
| JG70-10 | 16 | 12 | 3.7 | 61 | 33 | 23 | 10.5 | 2.0 | |
| JG95-8 | 18 | 14 | 4.2 | 67 | 36 | 26 | 8.5 | 2.0 | |
| JG95-10 | 18 | 14 | 4.2 | 67 | 36 | 26 | 10.5 | 2.0 | |
| JG95-12 | 18 | 14 | 4.2 | 67 | 36 | 26 | 12.5 | 2.0 | |
| JG120-10 | 20 | 16 | 4.8 | 75 | 43 | 29 | 10.5 | 2.0 | |
| JG120-12 | 20 | 16 | 4.8 | 75 | 43 | 29 | 12.5 | 2.0 | |
| JG120-14 | 20 | 16 | 4.8 | 75 | 43 | 29 | 14.5 | 2.0 | |
| JG120-16 | 20 | 16 | 4.8 | 75 | 43 | 29 | 16.5 | 2.0 | |
| JG150-10 | 22 | 17 | 4.0 | 91 | 57 | 32 | 10.5 | 2.5 | |
| JG150-12 | 22 | 17 | 4.0 | 91 | 57 | 32 | 12.5 | 2.5 | |
| JG150-14 | 22 | 17 | 4.0 | 91 | 57 | 32 | 14.5 | 2.5 | |
| JG150-16 | 22 | 17 | 4.0 | 91 | 57 | 32 | 16.5 | 2.5 | |
| JG185-10 | 24 | 19 | 5.0 | 96 | 59 | 35 | 10.5 | 2.5 | |
| JG185-12 | 24 | 19 | 5.0 | 96 | 59 | 35 | 12.5 | 2.5 | |
| JG185-14 | 24 | 19 | 5.0 | 96 | 59 | 35 | 14.5 | 2.5 | |
| JG185-16 | 24 | 19 | 5.0 | 96 | 59 | 35 | 16.5 | 2.5 | |
| JG240-12 | 26 | 21 | 5.0 | 96 | 62 | 39 | 13.0 | 2.5 | |
| JG240-14 | 26 | 21 | 5.0 | 96 | 62 | 39 | 15.0 | 2.5 | |
| JG240-16 | 26 | 21 | 5.0 | 96 | 62 | 39 | 17.0 | 2.5 | |
| JG240-20 | 26 | 21 | 5.0 | 96 | 62 | 39 | 21.0 | 2.5 | |
| JG300-12 | 30 | 24 | 6.0 | 103 | 67 | 43 | 13.0 | 2.5 | |
| JG300-14 | 30 | 24 | 6.0 | 103 | 67 | 43 | 15.0 | 2.5 | |
| JG300-16 | 30 | 24 | 6.0 | 103 | 67 | 43 | 17.0 | 2.5 | |
| JG300-20 | 30 | 24 | 6.0 | 103 | 67 | 43 | 21.0 | 2.5 | |
| MODEL | D ±0.3 (MM) | D ±0.3 (MM) | L ±1.5 (MM) | L1 ±1.5 (MM) | S ±0.3 (MM) | N ±0.5 (MM) | W ±0.5 (MM) | WALL THICKNESS (MM) |
|---|---|---|---|---|---|---|---|---|
| DT-10 | 9 | 5.8 | 63 | 30 | 2.4 | 8 | 16 | 1.6 |
| DT-16 | 10 | 6.5 | 65 | 32 | 2.6 | 8 | 16 | 1.75 |
| DT-25 | 11 | 7.5 | 70 | 35 | 3.0 | 9 | 18 | 1.75 |
| DT-35ᵀ | 12 | 8.7 | 80 | 38 | 3.2 | 10 | 20 | 1.75 |
| DT-50ᵀ | 14 | 10.0 | 85 | 42 | 3.4 | 11.5 | 23 | 2.0 |
| DT-70 | 16 | 12.0 | 95 | 47 | 4.0 | 13 | 26 | 2.0 |
| DT-95 | 18 | 14.0 | 103 | 48 | 4.5 | 14 | 28 | 2.0 |
| DT-120 | 20 | 15.5 | 111 | 52 | 4.8 | 15 | 30 | 2.25 |
| DT-150ᵀ | 22 | 17.0 | 121 | 56 | 5.5 | 17 | 34 | 2.5 |
| DT-185 | 25 | 19.0 | 125 | 59 | 6.0 | 18 | 38 | 3.0 |
| DT-240 | 27 | 21.5 | 135 | 60 | 6.6 | 20 | 40 | 2.75 |
| DT-300 | 30 | 23.5 | 152 | 68 | 7.3 | 25 | 50 | 3.25 |
| DT-400 | 34 | 27.0 | 170 | 76 | 8.5 | 28 | 55 | 3.5 |
| DT-500 | 38 | 29.0 | 186 | 86 | 9.0 | 31 | 55 | 3.75 |
| DT-630 | 45 | 35.0 | 210 | 86 | 9.0 | 31 | 60 | 3.75 |
Získejte svůj Free Cable Lug
Vzorky poskytujeme zdarma, stačí nám říct, co potřebujete.
More Than Just a Cable Lug Manufacturer
At VIOX, we go beyond manufacturing Cable Lug by offering a suite of value-added services tailored to meet your project needs. Our commitment to excellence ensures that every customer receives personalized attention, expert guidance, and seamless support throughout their journey with us.
Servisní konzultace
Whether your Cable Lug requirements are straightforward or complex, our team provides expert advice and technical consultation. For more intricate projects, we offer in-depth engineering support to ensure optimal product selection and application.
Doporučení produktů
Unsure which Cable Lug suits your Power system? Our specialists provide free, customized recommendations based on your specific operational and environmental requirements, ensuring you get the perfect fit.
Logistická podpora
Pokud nemáte spolehlivého dopravce, můžeme vám zajistit přepravu z naší továrny na místo projektu bez příplatku. Náš logistický tým zajišťuje včasné a bezpečné dodání, aby váš projekt probíhal podle plánu.
Podpora při instalaci
Potřebujete pomoci s instalací? Náš technický tým je připraven zodpovědět vaše dotazy nebo poskytnout praktickou podporu. U větších projektů můžeme na místo vyslat i technika, který vám pomůže přímo na místě.
Často kladené otázky
Připravili jsme pro vás několik častých otázek našich klientů. Pokud zde váš dotaz není uveden, náš zákaznický servis je vám vždy k dispozici. Rádi si s vámi popovídáme.
How Can I Get a Quote for the Cable Lug
To get a quote for our Cable Lug, contact our customer service team. We are available 24/7. Just provide the specifics of your order like the type, size, and quantity. We’ll guide you through the entire ordering process.
Jaké je vaše MOQ pro objednávku?
Máme nízké MOQ neboli minimální objednací množství. Můžete si objednat pouze jednu jednotku a my vám dodáme zboží podle vašich požadavků.
Jaká je doba vyřízení mé objednávky?
The standard turnaround time for our Cable Lug is 7 to 10 business days. Delivery time may extend by up to 15 business days due to transit. For custom or bulk orders, we can discuss the turnaround time before finalizing your order.
Mohu před objednáním získat vzorek?
Ano, poskytujeme vzorky k posouzení a schválení. Vytvoření vzorků obvykle trvá 3 až 7 pracovních dnů.
Can You Make Cable Lug
Yes, we offer customized Cable Lug. Let us know your requirements, and our expert customer service team will work with you through the design process.
What is Your Warranty for the Cable Lug
We offer a 3-year warranty on all Cable Lugs we produce. This ensures we deliver high-quality products. Every product is thoroughly tested before delivery.
Some About Cable Lug
Co jsou kabelová oka a proč jsou důležitá?
Cable lugs are conductive fittings attached to the ends of electrical cables to facilitate connection to electrical terminals. They create a clean, secure termination point that maximizes electrical contact while protecting against connection failure.
The importance of cable lugs extends beyond simple connectivity:
- Zvýšení bezpečnosti: Properly installed cable lugs minimize the risk of electrical fires, shorts, and other hazards.
- Enhanced Conductivity: They ensure optimal electrical flow with minimal resistance.
- Extended Equipment Life: Quality cable terminations protect both the cable and connected equipment from damage.
- Soulad s předpisy: Many electrical codes and standards require appropriate cable terminations for safety and performance reasons.
Functions of Cable Lug
- Electrical: To provide a highly conductive, low-resistance path for current to flow from the cable to the termination point.
- Mechanical: To securely anchor the cable, preventing it from pulling loose due to vibration or tension.
Types of Cable Lug
Cable lugs come in various types and are made from different materials to suit specific electrical connection needs. The primary materials include:
Měděná oka: Made from high-conductivity copper (99.9% pure), these offer excellent electrical performance with minimal resistance and good tensile strength, making them ideal for applications requiring optimal efficiency.
Hliníková oka: Lightweight and cost-effective alternatives that gained popularity in the 1960s, though they required design improvements after early implementation issues with aluminum oxide formation.
Tinned Copper Lugs: Copper lugs with a protective tin coating (3-5 μm thick) that enhances corrosion resistance, making them suitable for harsh or humid environments.
Brass Lugs: Offering excellent durability and high-temperature resistance, these provide good corrosion protection, particularly in marine applications.
Design variations include ring terminals (circular end with a center hole), fork/spade terminals (open-ended design for easy installation/removal), and pin terminals (solid pin end for terminal blocks).Connection methods range from compression lugs requiring crimping tools to mechanical lugs using setscrews or shear-head bolts for secure attachment.
How to Choose the Right Cable Lug
Choosing the wrong lug can compromise the entire connection. Follow these steps for proper cable lug sizing and selection:
- Match the Conductor Material: Use copper lugs for copper cables, aluminum lugs for aluminum cables. Critically, use bi-metal lugs whenever connecting aluminum cable to copper equipment/terminals.
- Determine Correct Conductor Size (AWG/kcmil or mm²): This is non-negotiable. The lug must be precisely sized for the cable gauge (e.g., 4 AWG, 2/0 AWG, 25mm², 120mm²). Using a lug that’s too small means the cable won’t fit; too large results in a poor crimp, high resistance, and potential failure. Refer to manufacturer cable lug sizing charts.
[Image: Example section of a cable lug sizing chart] - Verify Stud Hole Size: The hole in the lug’s tongue must match the diameter of the terminal stud or bolt it will be attached to (e.g., 1/4″, 3/8″, M6, M10). An oversized hole leads to poor contact.
- Consider Voltage and Current Rating: While often determined by cable size, ensure the lug itself (especially mechanical types) is rated appropriately for the system’s voltage and expected continuous/peak current.
- Assess Environmental Conditions: Will the connection be exposed to moisture, salt, chemicals, or high temperatures? This dictates the need for tinned copper, specific plating, or sealed connections (using heat shrink).
- Check for Required Standards and Certifications: For many applications (especially industrial, utility, and safety-critical), lugs must meet specific standards. Look for markings indicating compliance (e.g., UL Listed lugs(UL 486A-486B), CSA Certified, DIN). Using certified components ensures tested performance and safety.
How to Install Cable Lugs Correctly
Proper cable lug installation is just as important as correct selection. An improper crimp is a failure waiting to happen. Here’s how to crimp cable lugs effectively:
Gather Your Tools & Materials
- Correctly sized cable lugs
- Cable/wire
- Calibrated cable lug crimping tool with the correct die set specifically designed for the lug size and type (Hexagonal dies are common for larger lugs; indent types for smaller ones). Using pliers or the wrong tool will result in a faulty crimp.
- Cable stripper
- Wire brush (essential for aluminum conductors)
- Oxide inhibitor compound (essential for aluminum conductors)
- Optional: Heat shrink tubing and heat gun
Prepare the Cable End
- Strip the insulation back to the correct length specified by the lug manufacturer (usually equal to the barrel depth). Avoid nicking conductor strands.
- For aluminum cables: Vigorously brush the exposed conductor strands to remove the surface oxide layer immediately before inserting into the lug. Apply oxide inhibitor compound liberally to the strands.
Insert Cable into Lug Barrel
- Twist stranded conductors slightly (if needed) to keep strands together.
- Insert the prepared conductor fully into the lug barrel. If the lug has a sight hole (inspection window), verify the conductor is visible, confirming full insertion.
The Critical Step: Crimping the Lug
- Here’s the deal: The crimp physically molds the lug barrel and conductor into a solid, void-free mass.
- Select the correct die set for your crimping tool, matching the lug size and type (often marked on the lug).
- Position the lug correctly within the dies according to the tool/lug manufacturer’s instructions (crimp location is often marked on the lug barrel). For long barrel lugs, multiple crimps may be required.
- Activate the crimping tool (manual, hydraulic, or battery-powered). Ensure the tool completes its full crimping cycle (ratchet tools will typically only release after a full cycle). Do not under-crimp or over-crimp.
Inspect the Crimp Quality
- Don’t skip this step! A visual and mechanical check is vital.
- Visual Check: Look for the die code marking embossed on the crimped barrel (confirms correct die was used). The crimp should be uniform, with no excessive flashing (metal squeezed out sideways). For sight hole lugs, ensure the conductor is still visible.
- Mechanical Check: Gently pull on the cable to ensure it’s securely held within the lug. A proper crimp creates a bond stronger than the cable itself.
Optional: Sealing the Connection
- Slide appropriately sized heat shrink tubing over the lug barrel and onto the cable insulation.
- Use a heat gun to shrink the tubing evenly. This provides electrical insulation, mechanical strain relief, and seals the connection against moisture and contaminants.
Cable Lugs vs. Alternatives
While cable lugs are standard for terminating larger cables onto studs or bus bars, other connectors exist:
- Terminal Blocks: Used for joining multiple wires together or distributing power in enclosures. Better for smaller gauge wires and situations requiring easy modification.
- Splices (Butt Splices/Parallel Splices): Used for joining two cables end-to-end or tapping off a cable run.
- Pin Terminals/Ferrules: Used to consolidate wire strands for insertion into screw clamp terminals.
Cable lugs excel where a secure, high-current, direct termination to equipment or a stud is required.
Cable Lug Manufacturing Process
The process starts with selecting high-conductivity EC-grade copper or aluminum, typically in tube form (for tubular lugs) or sheet form (for stamped lugs). This material is precisely cut to length.
Next, specialized machines form the material into the lug’s characteristic barrel (for the cable) and palm (the flat mounting part) through processes like pressing, stamping, or forging. Holes for bolts or screws are then punched into the palm, and edges are smoothed.
For enhanced flexibility, some lugs undergo annealing (heat treatment). A critical step is surface treatment, most commonly tin electroplating, which provides vital corrosion resistance.
Finally, lugs are stamped with identification marks (size, manufacturer), undergo rigorous quality control (checking dimensions, strength, conductivity), and are then cleaned and packaged for distribution. Modern manufacturing heavily relies on automated production lines for efficiency and consistency.
Normy a certifikace kabelových ok
Kvalitní kabelová oka odpovídají různým průmyslovým normám:
- UL (Underwriters Laboratories): Zajišťuje bezpečnostní a výkonnostní požadavky
- CSA (Kanadská asociace pro normalizaci): Kanadská certifikace podobná UL
- IEC (Mezinárodní elektrotechnická komise): Mezinárodní normy pro elektrické součástky
- NEMA (Národní asociace výrobců elektrických zařízení): Průmyslové normy pro elektrická zařízení
- IEEE (Institut elektrotechnických a elektronických inženýrů): Technické normy pro elektrické systémy
Při nákupu kabelových koncovek se zaměřte na tyto certifikace, které zajišťují kvalitu a bezpečnost.
Yueqing & VIOX ELECTRIC: Leading the Cable Lug Market
Recognized as “China’s electrical town,” Yueqing is a global manufacturing powerhouse for cable lugs, bolstered by strategic government support that maintains its competitive edge despite market challenges.
Prominent manufacturers like VIOX ELECTRIC exemplify Yueqing’s commitment to quality and significantly contribute to its strong international market position.
With the global cable lug market projected to grow robustly (5.4%-9.5% CAGR through 2033), Yueqing, featuring key players like VIOX ELECTRIC, stands as the premier source for high-quality, reliable electrical components.
Request an Cable Lug
VIOX Electric is ready to assist you with your OEM Cable Lug needs. We offer high-quality and cost-effective solutions.