DTLL
Mingxu
This innovative lug utilizes high-integrity friction welding to bond an aluminum conductor barrel to a copper terminal palm, eliminating galvanic corrosion issues in dissimilar metal connections. Compliant with IEC 61238-1 and BS 4572 standards, it supports conductor cross-sections from 16 mm² to 1000 mm² in low to medium-voltage applications (up to 10 kV). Its reusable bolted design facilitates easy maintenance and reconfiguration, making it ideal for electrical systems requiring periodic inspection or modification.
The lug features an aluminum barrel (1060 alloy, 99.6% purity) with 60% IACS conductivity for connection to aluminum conductors, and a copper palm (C11000 ETP) with 97% IACS conductivity for interface with copper equipment. The friction-welded joint achieves a tensile strength of ≥150 MPa and maintains a resistivity of ≤1.5 µΩ·cm across the metal transition.
The copper palm includes precision-machined bolt holes (M6 to M20) with tinned surfaces to prevent oxidation and ensure consistent torque retention. This bolted design allows for reusable connections with proper torque maintenance, facilitating equipment maintenance without replacing the lug itself.
Featuring a bell-mouthed conductor entry, the lug prevents strand damage during installation. The aluminum barrel incorporates internal longitudinal serrations that enhance crimp retention by 30% compared to smooth designs. A pre-applied conductive anti-oxidation compound ensures long-term conductivity by inhibiting oxide formation on aluminum strands.
In distribution panels and switchgear, the lug provides detachable connections between aluminum feeder cables and copper busbars, allowing for easy panel reconfiguration and equipment upgrades.
The lug facilitates connections between aluminum array cables and copper terminals in solar combiner boxes and wind turbine junction boxes, supporting renewable energy system maintenance and expansion.
In manufacturing facilities, the lug connects aluminum power cables to copper terminals on motors, drives, and control equipment, allowing for easy equipment replacement and system modifications.
Friction welding creates a metallurgical bond between copper and aluminum, eliminating the electrolyte gap that causes galvanic corrosion in mechanical connections. This results in a more reliable, lower-resistance connection with longer service life.
Recommended torque values range from 10 N·m for M6 bolts to 60 N·m for M20 bolts, following the specifications in BS 4572 to ensure proper contact pressure without damaging the copper palm.
Yes, the bolted design allows for multiple reconnections when properly maintained. After each disconnection, inspect the conductor barrel for damage and reapply anti-oxidation compound before reconnection.
Yes, the tin-plated copper palm and corrosion-resistant aluminum barrel provide adequate protection for outdoor use. For coastal or highly polluted environments, additional protection with heat-shrink tubing is recommended to extend service life.
| ltem No. | Cross sectio n(mm²) | A | B | C | Bolt |
| DTLL-16/70-12/B | 16/70 | φ24±1 | 92±2 | φ23±0.2 | M12×1.25 |
| DTLL-50/150-12/B | 50/150 | φ30±1 | 108±2 | φ28±0.2 | M16×1.25 |
| DTLL-95/240-16/B | 95/240 | φ35±1 | 129±2 | φ34±0.2 | M16×1.25 |
| DTLL-185/400-16/B | 185/400 | φ50±1 | 196±3 | φ44±0.2 | M22×1.25 |
This innovative lug utilizes high-integrity friction welding to bond an aluminum conductor barrel to a copper terminal palm, eliminating galvanic corrosion issues in dissimilar metal connections. Compliant with IEC 61238-1 and BS 4572 standards, it supports conductor cross-sections from 16 mm² to 1000 mm² in low to medium-voltage applications (up to 10 kV). Its reusable bolted design facilitates easy maintenance and reconfiguration, making it ideal for electrical systems requiring periodic inspection or modification.
The lug features an aluminum barrel (1060 alloy, 99.6% purity) with 60% IACS conductivity for connection to aluminum conductors, and a copper palm (C11000 ETP) with 97% IACS conductivity for interface with copper equipment. The friction-welded joint achieves a tensile strength of ≥150 MPa and maintains a resistivity of ≤1.5 µΩ·cm across the metal transition.
The copper palm includes precision-machined bolt holes (M6 to M20) with tinned surfaces to prevent oxidation and ensure consistent torque retention. This bolted design allows for reusable connections with proper torque maintenance, facilitating equipment maintenance without replacing the lug itself.
Featuring a bell-mouthed conductor entry, the lug prevents strand damage during installation. The aluminum barrel incorporates internal longitudinal serrations that enhance crimp retention by 30% compared to smooth designs. A pre-applied conductive anti-oxidation compound ensures long-term conductivity by inhibiting oxide formation on aluminum strands.
In distribution panels and switchgear, the lug provides detachable connections between aluminum feeder cables and copper busbars, allowing for easy panel reconfiguration and equipment upgrades.
The lug facilitates connections between aluminum array cables and copper terminals in solar combiner boxes and wind turbine junction boxes, supporting renewable energy system maintenance and expansion.
In manufacturing facilities, the lug connects aluminum power cables to copper terminals on motors, drives, and control equipment, allowing for easy equipment replacement and system modifications.
Friction welding creates a metallurgical bond between copper and aluminum, eliminating the electrolyte gap that causes galvanic corrosion in mechanical connections. This results in a more reliable, lower-resistance connection with longer service life.
Recommended torque values range from 10 N·m for M6 bolts to 60 N·m for M20 bolts, following the specifications in BS 4572 to ensure proper contact pressure without damaging the copper palm.
Yes, the bolted design allows for multiple reconnections when properly maintained. After each disconnection, inspect the conductor barrel for damage and reapply anti-oxidation compound before reconnection.
Yes, the tin-plated copper palm and corrosion-resistant aluminum barrel provide adequate protection for outdoor use. For coastal or highly polluted environments, additional protection with heat-shrink tubing is recommended to extend service life.
| ltem No. | Cross sectio n(mm²) | A | B | C | Bolt |
| DTLL-16/70-12/B | 16/70 | φ24±1 | 92±2 | φ23±0.2 | M12×1.25 |
| DTLL-50/150-12/B | 50/150 | φ30±1 | 108±2 | φ28±0.2 | M16×1.25 |
| DTLL-95/240-16/B | 95/240 | φ35±1 | 129±2 | φ34±0.2 | M16×1.25 |
| DTLL-185/400-16/B | 185/400 | φ50±1 | 196±3 | φ44±0.2 | M22×1.25 |
