DTL-F
Mingxu
This rugged component utilizes induction-assisted friction welding to create a permanent bond between its aluminum conductor barrel and copper terminal section, ensuring superior mechanical strength and electrical performance. Compliant with IEC 61238-1 and UL 486B standards, it supports conductor cross-sections from 16 mm² to 1000 mm² in low to medium-voltage industrial systems (up to 10 kV). Its robust construction and enhanced corrosion resistance make it indispensable for manufacturing facilities, processing plants, and heavy machinery applications where downtime is costly and reliability is paramount.
The lug features a 99.5% pure aluminum barrel (1050 alloy) for crimping to aluminum conductors and a 99.9% ETP copper terminal section (C11000) for connection to equipment. The welded joint achieves a minimum tensile strength of 160 MPa and maintains a conductivity of 97% IACS in the copper section and 61.2% IACS in the aluminum section, ensuring efficient current transfer in high-power applications.
The aluminum barrel incorporates deep longitudinal serrations that enhance crimp retention force by 40% compared to standard designs, maintaining connection integrity under continuous vibration up to 2000 Hz – common in industrial machinery applications. The copper terminal features precision-machined bolt holes (M8 to M24) with thread-locking grooves to prevent loosening under cyclic loading.
The copper terminal undergoes a tin-lead plating process (10-15 µm thickness) for enhanced corrosion resistance, while the aluminum barrel features a chromate conversion coating and pre-applied anti-oxidation compound. This dual-protection system ensures reliable performance in industrial environments with chemical exposure, high humidity, and temperature fluctuations.
Engineered to perform reliably across a temperature range of -40°C to 110°C, the lug accommodates the extreme thermal conditions found in industrial environments, from cold storage facilities to high-temperature manufacturing processes. This temperature tolerance ensures consistent performance through thermal cycling without mechanical degradation.
In manufacturing facilities, the lug connects aluminum power cables to copper terminals on motors, drives, and control panels for heavy machinery, including stamping presses, injection molding machines, and conveyor systems where vibration resistance is critical.
The lug provides reliable connections in chemical processing plants, refineries, and pulp mills, where it withstands exposure to industrial contaminants, temperature extremes, and vibration from processing equipment. Its corrosion resistance makes it suitable for aggressive environments.
In steel mills and foundries, the lug handles high-current connections for electric arc furnaces, rolling mills, and casting equipment, maintaining performance despite the high-temperature environments and mechanical stress typical in metal production.
The lug is ideal for mining equipment and heavy industrial applications, providing reliable power connections for crushers, conveyors, and processing equipment in environments with dust, vibration, and temperature extremes.
Yes, when properly installed with ex d flameproof enclosures and certified accessories, the lug is suitable for use in hazardous areas classified as Zone 2 (gas) and Zone 22 (dust) in accordance with ATEX directives, providing safe operation in potentially explosive atmospheres.
In heavy-vibration environments, torque verification is recommended every 6 months, with full inspection including thermographic scanning annually to identify potential high-resistance connections before they cause failures. This proactive maintenance helps prevent unplanned downtime.
The industrial version features thicker material sections, enhanced serration depth for vibration resistance, superior plating thickness (10-15 µm vs. standard 5-8 µm) for corrosion protection, and higher tensile strength ratings specifically engineered for the harsh conditions of industrial environments.
Aluminum conductors require oxide removal using a wire brush followed by application of the included anti-oxidation compound to ensure proper conductivity. The conductor end should be cut square and inserted to the marked depth in the barrel before crimping to ensure optimal performance and mechanical strength.
| ltem No. | D | d | W | d1 | L1 | L | S |
| DTL-F-10 | 16 | 4.5 | 14 | 8.5 | 42 | 87 | 4.2 |
| DTL-F-16 | 16 | 5.5 | 14 | 8.5 | 42 | 87 | 4.2 |
| DTL-F-25 | 16 | 7 | 14 | 8.5 | 42 | 87 | 4.2 |
| DTL-F-35 | 16 | 8.5 | 14 | 8.5 | 42 | 87 | 4.2 |
| DTL-F-50 | 20 | 9.5 | 17 | 10.5 | 50 | 100 | 5.2 |
| DTL-F-70 | 20 | 11.5 | 17 | 10.5 | 50 | 100 | 5.2 |
| DTL-F-95 | 20 | 13 | 17 | 10.5 | 50 | 100 | 5.2 |
| DTL-F-120 | 25 | 15 | 21 | 13 | 60 | 120 | 6.2 |
| DTL-F-150 | 25 | 16.5 | 21 | 13 | 60 | 120 | 6.2 |
| DTL-F-185 | 32 | 18 | 25 | 13 | 60 | 125 | 7.2 |
| DTL-F-240 | 32 | 19.5 | 25 | 13 | 60 | 125 | 7.2 |
| DTL-F-300 | 34 | 23.5 | 30 | 13 | 65 | 145 | 8.0 |
| DTL-F-400 | 40 | 26 | 32 | 13 | 70 | 150 | 8.0 |
| DTL-F-500 | 40 | 29 | 32 | 13 | 70 | 150 | 8.0 |
This rugged component utilizes induction-assisted friction welding to create a permanent bond between its aluminum conductor barrel and copper terminal section, ensuring superior mechanical strength and electrical performance. Compliant with IEC 61238-1 and UL 486B standards, it supports conductor cross-sections from 16 mm² to 1000 mm² in low to medium-voltage industrial systems (up to 10 kV). Its robust construction and enhanced corrosion resistance make it indispensable for manufacturing facilities, processing plants, and heavy machinery applications where downtime is costly and reliability is paramount.
The lug features a 99.5% pure aluminum barrel (1050 alloy) for crimping to aluminum conductors and a 99.9% ETP copper terminal section (C11000) for connection to equipment. The welded joint achieves a minimum tensile strength of 160 MPa and maintains a conductivity of 97% IACS in the copper section and 61.2% IACS in the aluminum section, ensuring efficient current transfer in high-power applications.
The aluminum barrel incorporates deep longitudinal serrations that enhance crimp retention force by 40% compared to standard designs, maintaining connection integrity under continuous vibration up to 2000 Hz – common in industrial machinery applications. The copper terminal features precision-machined bolt holes (M8 to M24) with thread-locking grooves to prevent loosening under cyclic loading.
The copper terminal undergoes a tin-lead plating process (10-15 µm thickness) for enhanced corrosion resistance, while the aluminum barrel features a chromate conversion coating and pre-applied anti-oxidation compound. This dual-protection system ensures reliable performance in industrial environments with chemical exposure, high humidity, and temperature fluctuations.
Engineered to perform reliably across a temperature range of -40°C to 110°C, the lug accommodates the extreme thermal conditions found in industrial environments, from cold storage facilities to high-temperature manufacturing processes. This temperature tolerance ensures consistent performance through thermal cycling without mechanical degradation.
In manufacturing facilities, the lug connects aluminum power cables to copper terminals on motors, drives, and control panels for heavy machinery, including stamping presses, injection molding machines, and conveyor systems where vibration resistance is critical.
The lug provides reliable connections in chemical processing plants, refineries, and pulp mills, where it withstands exposure to industrial contaminants, temperature extremes, and vibration from processing equipment. Its corrosion resistance makes it suitable for aggressive environments.
In steel mills and foundries, the lug handles high-current connections for electric arc furnaces, rolling mills, and casting equipment, maintaining performance despite the high-temperature environments and mechanical stress typical in metal production.
The lug is ideal for mining equipment and heavy industrial applications, providing reliable power connections for crushers, conveyors, and processing equipment in environments with dust, vibration, and temperature extremes.
Yes, when properly installed with ex d flameproof enclosures and certified accessories, the lug is suitable for use in hazardous areas classified as Zone 2 (gas) and Zone 22 (dust) in accordance with ATEX directives, providing safe operation in potentially explosive atmospheres.
In heavy-vibration environments, torque verification is recommended every 6 months, with full inspection including thermographic scanning annually to identify potential high-resistance connections before they cause failures. This proactive maintenance helps prevent unplanned downtime.
The industrial version features thicker material sections, enhanced serration depth for vibration resistance, superior plating thickness (10-15 µm vs. standard 5-8 µm) for corrosion protection, and higher tensile strength ratings specifically engineered for the harsh conditions of industrial environments.
Aluminum conductors require oxide removal using a wire brush followed by application of the included anti-oxidation compound to ensure proper conductivity. The conductor end should be cut square and inserted to the marked depth in the barrel before crimping to ensure optimal performance and mechanical strength.
| ltem No. | D | d | W | d1 | L1 | L | S |
| DTL-F-10 | 16 | 4.5 | 14 | 8.5 | 42 | 87 | 4.2 |
| DTL-F-16 | 16 | 5.5 | 14 | 8.5 | 42 | 87 | 4.2 |
| DTL-F-25 | 16 | 7 | 14 | 8.5 | 42 | 87 | 4.2 |
| DTL-F-35 | 16 | 8.5 | 14 | 8.5 | 42 | 87 | 4.2 |
| DTL-F-50 | 20 | 9.5 | 17 | 10.5 | 50 | 100 | 5.2 |
| DTL-F-70 | 20 | 11.5 | 17 | 10.5 | 50 | 100 | 5.2 |
| DTL-F-95 | 20 | 13 | 17 | 10.5 | 50 | 100 | 5.2 |
| DTL-F-120 | 25 | 15 | 21 | 13 | 60 | 120 | 6.2 |
| DTL-F-150 | 25 | 16.5 | 21 | 13 | 60 | 120 | 6.2 |
| DTL-F-185 | 32 | 18 | 25 | 13 | 60 | 125 | 7.2 |
| DTL-F-240 | 32 | 19.5 | 25 | 13 | 60 | 125 | 7.2 |
| DTL-F-300 | 34 | 23.5 | 30 | 13 | 65 | 145 | 8.0 |
| DTL-F-400 | 40 | 26 | 32 | 13 | 70 | 150 | 8.0 |
| DTL-F-500 | 40 | 29 | 32 | 13 | 70 | 150 | 8.0 |
