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DT Copper Lug

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DT Copper Lug

DT Copper Lugs focus on providing a secure connection between cables and electrical equipment. With their excellent conductivity and stable mechanical strength, they ensure safe and reliable transmission of high currents. Their contact surfaces have been precisely processed to effectively reduce contact resistance, thereby minimizing heat generation and improving the efficiency of electrical system operation. These lugs are easy to install, have a rational structure, and can adapt to the crimping requirements of different cables, maintaining stability and durability over long-term operation. They are commonly used in transformers, power distribution equipment, and high and low voltage switch systems to help establish a secure electrical circuit, ensuring efficient operation of equipment in complex power environments and improving overall operational reliability and safety.

Pure copper
Item NO. Φ D d L L1 W S
DT-1-10 8.8 9 5.2 62 30 16 2.5
DT-1-16 8.8 10 6.1 68 31 16 2.5
DT-1-25 8.8 11 7.1 70 34 18 2.7
DT-1-35 10.8 12 8.5 80 36 20 3
DT-1-50 10.8 14 9.8 86 39 23 3.4
DT-1-70 13 16 11.5 95 44 26 3.8
DT-1-95 13 18 13.5 104 47 28 4.2
DT-1-120 14.8 20 15 112 49 30 4.7
DT-1-150 14.8 22 17 120 52 34 5.5
DT-1-185 17 25 18.5 126 56 37 5.8
DT-1-240 17 27 21.5 137 60 40 6.5
DT-1-300 21 31 24 158 68 45 8
DT-1-400 21 34 27 175 78 52 9
DT-1-500 21 38 30 188 82 60 10
DT-1-630 21 45 34.2 215 86 78 12
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About Us
Shaoxing Sweld Electric Co., Ltd.

Shaoxing Sweld Electric Co., Ltd. was established in 2018, located in Shengzhou, Shaoxing, China, the hometown of Shaoxing Opera. Covers an area of 3000 square meters, has a professional technical team and sales elite, a total of more than 50.                                                            

The factory mainly produces exothermic welding powder and a complete set of products, including Ground rods, Ground wire, Stranded Wire, all kinds of electrical hardware connection parts and lightning rod products. We have an annual production capacity of 500 tons of exothermic welding powder, providing various packaging solutions. Equipped with 7 high-speed CNC machining centers, with a daily production capacity of 180 sets of exothermic welding molds, it can provide customers with real-time design and manufacturing molding.                              

 Sweld has passed ISO9001 quality management system certification, ISO14001 environmental management system certification, and ISO45001 occupational health and safety management system certification. And we also provide exothermic welding powder export special dangerous package certificate, exothermic welding molds export license, all kinds of products have passed the national certification laboratory product testing certification.                            


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What type of terminal structure is the DT Copper Lug?

The DT Copper Lug is a copper terminal specifically designed for reliable connections between cables and electrical equipment. Its structural design reflects the high requirements of industrial terminals for conductivity, mechanical strength, and ease of installation. It belongs to the category of tubular compression copper lugs, also known as cold-press terminals. Its core feature is the tight fixing of the conductor using a tubular compression barrel, achieving a stable, low-impedance metal connection.

The typical structure of a DT Copper Lug includes three parts: the compression barrel, the bolt/nut hole, and the end connection surface. The compression barrel accommodates the cable conductor; whether it's a single-strand copper wire or a multi-strand wire, a secure metal cold-weld contact is formed after crimping, ensuring low contact resistance during current transmission. The bolt hole section is used to fix the terminal to busbars, switchgear, or electrical equipment. Different models of DT Copper Lug offer single-hole, double-hole, or even multi-hole designs to suit various installation needs. The end connection surface is polished and tin-plated to enhance conductivity and corrosion resistance.

Compared to series such as SC Copper Lug and JG Copper Lug, the DT Copper Lug focuses more on high current load capacity and mechanical stability. Some DT Copper Lug models also feature thickened tube walls or anti-rotation flanges, improving crimping strength and long-term stability. This structural design maintains reliable connections in high-vibration, high-impact, or long-term load environments, preventing loosening or poor contact.

In practical applications, the tubular compression structure of the DT Copper Lug is ideal for medium- and high-voltage power distribution systems, industrial automation equipment, and new energy projects. For example, in power distribution cabinet wiring, industrial motor control systems, and wind or photovoltaic power generation systems, the DT Copper Lug can withstand long-term high-current operation while maintaining low temperature rise and high stability. Furthermore, the tubular design facilitates standardized production and rapid on-site crimping, improving installation efficiency and safety.

Does the DT Copper Lug utilize cold extrusion and integrated crimping tube manufacturing?

The manufacturing process of DT Copper Lugs directly impacts their conductivity, mechanical strength, and service life. To meet the demands of industrial equipment, high-current applications, and high-vibration environments, high-quality DT Copper Lugs typically utilize cold extrusion and an integrated crimping tube manufacturing process. This process differs from traditional welding or splicing terminals and significantly improves the reliability and safety of the terminals.

In the cold extrusion process, high-purity copper rods (such as T2 pure copper or C1100 electrolytic copper) are formed into a complete terminal tube body at room temperature using a high-pressure extrusion machine. The entire terminal is formed in a single process. The main advantages of this process are:

1. Complete and seamless structure: Avoids potential problems such as poor contact, stress concentration, or cracks that may occur in welded or spliced ​​terminals.
2. High mechanical strength: Cold extrusion creates a dense metal crystal structure, improving the terminal's tensile strength, impact resistance, and fatigue resistance.
3. Excellent conductivity: The complete metal crystal structure reduces energy loss during current transmission, ensuring low contact resistance and low temperature rise.
4. High dimensional accuracy: Cold extrusion allows for precise control of the inner diameter, wall thickness, and length of the crimping barrel, facilitating matching with standard cables and ensuring consistent crimping quality.

Integrated crimping tube manufacturing means that the crimping barrel and the end connection surface of the DT Copper Lug are a single structure, forming a continuous metal structure and avoiding potential safety hazards associated with welding or splicing processes. In high-current or heavy-load environments, integrated terminals can withstand higher mechanical stress and vibration, ensuring long-term stable connection.

To further improve performance, high-quality DT Copper Lugs undergo annealing treatment after forming, giving the copper material good ductility. Annealed copper is easier to form a tight cold-welded contact, improving the pull-out force and mechanical reliability after crimping. In addition, the terminal surface is usually tin-plated to enhance corrosion resistance while maintaining excellent conductivity.

Therefore, DT Copper Lugs, manufactured using cold extrusion molding and integrated crimping tube manufacturing processes, outperform traditional terminals in terms of mechanical strength, conductivity, and long-term reliability, making them ideal for high-load, high-current applications in industrial, power, automation equipment, and new energy systems.

Is the DT Copper Lug Suitable for Outdoor or High-Humidity Environments?

The suitability of DT Copper Lugs for outdoor or high-humidity environments primarily depends on the quality of the copper material, surface treatment, manufacturing process, and overall structural design. Outdoor environments often involve factors such as humidity, temperature fluctuations, salt spray, or chemical corrosion. If the terminal material or processing is inadequate, it can easily lead to the formation of oxide layers or corrosion points, resulting in increased contact resistance, unstable current transmission, and even affecting the safe operation of the entire electrical system. High-quality DT Copper Lugs use high-purity T2 or C1100 electrolytic copper as the conductor material, ensuring excellent conductivity.  The copper is also annealed to improve ductility, allowing the terminal to form a tight, low-resistance cold-welded connection with the cable conductor after crimping, thus maintaining stable temperature rise during long-term high-load operation.

To adapt to outdoor and high-humidity environments, the surface of DT Copper Lugs is usually treated with electroplating or hot-dip tin plating. The tin plating effectively isolates air, moisture, and corrosive chemical media, significantly extending the service life of the terminal and ensuring low contact resistance even in humid or salt spray environments. Some models of DT Copper Lugs feature thicker tin plating or hot-dip tin plating, making them more suitable for coastal or highly corrosive industrial environments. Furthermore, DT Copper Lugs using a cold-extrusion integrated crimping tube process ensure a seamless overall structure, fundamentally reducing potential corrosion weak points at welds or joints, allowing the terminal to maintain mechanical and electrical stability in outdoor or high-humidity environments for extended periods.

Combined with the professional expertise of Shaoxing Sweld Electric Co., Ltd., DT Copper Lugs offer even greater reliability in outdoor applications. Shaoxing Sweld Electric Co., Ltd. strictly controls product quality from raw material selection onwards, conducting full-process inspection, testing, and recording, covering raw materials, production processes, and final product inspection, ensuring that every terminal meets high standards. The company not only provides high-quality products but also offers a full range of services, from pre-sales consultation and Q&A to in-sales technical support and after-sales follow-up and guidance, ensuring that customers receive stable and reliable electrical connection solutions in any environment. Shaoxing Sweld Electric Co., Ltd. firmly believes that reliable product quality and continuously optimized user experience are the foundation for the survival and development of the company.

In practical applications, the DT Copper Lugs produced by Shaoxing Sweld Electric Co., Ltd. have been widely used in outdoor distribution boxes, photovoltaic energy storage systems, wind power equipment, charging piles, marine electrical systems, and industrial automation equipment in high-humidity environments. Through the use of high-purity copper materials, tin plating treatment, and integrated cold extrusion molding technology, combined with Shaoxing Sweld Electric Co., Ltd.'s comprehensive quality control system, the DT Copper Lugs can provide safe, low-impedance, and stable electrical connections in outdoor and high-humidity environments for extended periods, meeting the stringent requirements for high reliability and safety in the industrial and new energy sectors.