Basically; you need a mold and a press machine to produce the cable lug. You have the option of using manual, semi-automatic, or fully automatic cable lug molds. And the press machine might be a hydraulic or an eccentric-mechanical press machine. The raw material (annealed copper or aluminum pipe) has to be cut to the correct size and must be countersunk.

A Mold (Mould or Die) is a tool used to shape an object formed of malleable material. We manufacture newly designed manual and fully automatic molds.

A Machine is an apparatus using mechanical power and has several parts, each with a definite function and performing a particular task. We manufacture Orbital Pipe Cutting Machines, Countersinking Machines, Vibrating Feeders, Hydraulic Press Machines, and Pipe Feeder Magazines. We call our Fully Automatic Molds “Fully Automatic Machines” when we use them with PLC Controlled Vibrating Feeders and Press Machine.

A Production Line is an arrangement of machines in a factory, where the products pass from machine to machine until they are finished. We manufacture the entire production line from raw material loading to the finished product process. Pipe Feeding Magazine, Orbital Pipe Cutting Machine, Countersink Machine, PLC Controlled Vibrating Feeder, Fully Automatic Cable Lug Mold, and Hydraulic Power Press Machine are in this production line. This production line allows producing approximately one cable lug per second.

You’ll need to order a different mold for each distinct element in your production plan. It is important for production optimization to select molds in fully automatic, semi-automatic, or manual systems based on your annual production target.

Fully Automatic Production Line

1 – Pipe Feeding Magazine or Reel Wheel Opener

2 – Orbital Pipe Cutting Machine 

3 – Countersinking Machine

4 – Hydraulic Power Press Machine: (According to cable lug dimensions: 35 tons for 6/70 mm2;
50 tons for:70/240 mm2; 120 tons for: 240/1000 mm2).
You can use your existing Power Press Machines, but the table-hammer distance of the machine must be 300 mm minimum.

5 – Vibrating Feeder with PLC Control System
for molds. 

6 – Fully automatic mold (a mold for each different cable lug size) (Minimum order quantity for mold is 5)

Semi-Automatic Production Line (For One Cable Lug)

1 – Pipe Feeding Magazine or Reel Wheel Opener

2 – Orbital Pipe Cutting Machine 

3 – Countersinking Machine

4 – Custom Multi-Head Rotary Table Hydraulic Type Press Machine: (According to cable lug dimensions: 35 tons for 6/120 mm2; 50 tons for 6/400 mm2; 120 tons for 240/1000 mm2).

5 – Mold group connected to Custom Multi-Head Rotary Table Hydraulic Type Press Machine for each different cable lug.

Semi-Automatic Production Line (For Double Cable Lug)

1 – Pipe Feeding Magazine or Reel Wheel Opener

2 – Orbital Pipe Cutting Machine 

3 – Countersinking Machine

4 – Custom Multi-Head Rotary Table Hydraulic Type Press Machine:

(According to cable lug dimensions: 35 tons for 6/120 mm2; 50 tons for 6/400 mm2; 120 tons for 240/1000 mm2).

5 – Mold Group, (a mold group for each different cable lug.)

6 – Hydraulic Type Press Machine

Manuel Production Line (For Double Cable Lugs)

1 – Pipe Feeding Magazine or Reel Wheel Opener

2 – Orbital Pipe Cutting Machine 

3 – Countersinking Machine

4 – Hydraulic or Eccentric Type Mechanical Press Machine: (According to cable lug dimensions: 35 tons for 6/70 mm2; 50 tons for 70/240 mm2; 120 tons for 240/1000 mm2). You can use your existing Power Press Machines, but the table-hammer distance of the machine must be 300 mm minimum.

5 – Manual mold (a mold for each different cable lug size)

A MANUAL CABLE LUG MOLD is able to produce 3.000 / 5.000 cable lugs in 10 hours.

A SEMI-AUTOMATIC CABLE LUG MOLD is able to produce 6.000 / 10.000 lugs in 10 hours.

A FULLY AUTOMATIC CABLE LUG MOLD can produce one cable lug per second. Approximately 30.000 cable lugs can be produced in 10 hours.

Yes, you can. But we do not recommend it.
The same metric section and same size but the various screw diameters cable lugs can be produced in the same mold.
However, for this process, some parts of the mold must be replaced, and these parts must be disassembled and reassembled with other parts by a professional.
It’s important to remember that replacing mold parts frequently reduces the mold’s lifespan.
These molds lose their warranty, if the disassemble/reassemble process, which has not been done by us and requires experience, is performed outside our control.

Yes.

Copper or aluminum pipes are utilized as raw materials in the manufacture of cable lugs. The raw material has to be cut to the required size. Cut pipe pieces have to countersink from both ends. These operations can be done manually. But you need human power in manual operations. Also, a lot of time is wasted.

A-KLP manufactures fully-automatic machines for these operations. ORBITAL PIPE CUTTING MACHINE and COUNTERSINKING MACHINE. A-KLP manufactures PIPE FEEDING MAGAZINE and REEL WHEEL OPENER for loading the raw material.

You need to cut the raw material to the required length of cable lug production. This can be done manually or with an automatic machine. A-KLP manufactures “ORBITAL PIPE CUTTING MACHINE”. This machine cuts copper or aluminum pipes to the desired size automatically.

Click for detailed information:  Fully Automatic Orbital Pipe Cutting Machine

Pipe pieces cut to the required size with a manual or automatic pipe cutting machine should be countersunk on both sides before inserting into the fully automatic mold. A-KLP manufactures DOUBLE-SIDED COUNTERSINKING MACHINES. These machines automatically countersink pipe pieces from both sides approximately in 1-2 seconds.

For detailed information, please click

Double-Sided Countersinking Machine

Cable lugs are produced using copper or aluminum pipes. Pipes with a diameter of 05-16 mm are usually supplied as reel wheels. Reel wheel pipes are fed into the orbital pipe cutting machine after being automatically straightened in the REEL WHEEL OPENER.