CABLE LUGS MANUFACTURING (COPPER & ALUMINIUM)
[EIRI/EDPR/4227] J.C.: 2395XL
INTRODUCTION
Cable lugs are the devices used for connecting cable and wire conductors in electrical installations and equipment. These are used when permanent, direct fastening methods are not feasible or necessary. In general, lugs are fixed to cables and wires by inserting the conductor/s into the barrel (tube) of the device and then barrel is crimped, soldered or welded onto the conductor for secure mechanical and electrical joint. The connection end of the lug is then fastened to connection point by means of a bolt, screw, or spring clip. Numerous sizes, configurations and material types are available to suit particular applications.
Connector end of lug is typically chosen for its compatibility to the terminal type. Fork or U-shaped lugs are used for screw terminals; closed-ring or O-type lugs are used for bolt-on applications; and pin lugs are used for press-on terminals. A cable lug also serves as a cable-size reducer, thereby allowing thick cables to be attached to a connector with a smaller diameter.
Cable lugs are devices used for connecting cables to electrical appliances, other cables, surfaces, or mechanisms. The clamps that connect wires to an automotive battery are a common example of a cable lug, as are the ends of battery jumper cables. Designed to be easily installed and removed for repairs or maintenance, cable lugs area generally used when permanent, direct-fastening methods are not feasible or necessary.
COST ESTIMATION
Plant Capacity 1.75 MT/Day
Land & Building (2600 sq.mt.) Rs. 13.30 Lac
Plant & Machinery Rs. 25.90 Lac
Working Capital for 2 Months Rs. 6.08 Cr
Total Capital Investment Rs. 6.55 Cr
Rate of Return 65%
Break Even Point 26%
CONTENTS
INTRODUCTION
TYPES OF LUGS
(1) TUBULAR TERMINAL ENDS:
(2) RING TYPE TERMINAL ENDS:
(3) PIN TYPE TERMINAL ENDS:
(4) FORK TYPE TERMINAL END:
COMPRESSION CABLE LUGS
CRIMPING LUGS
WHAT IS CRIMPING?
WHAT ARE CRIMPING LUGS?
CABLE LUGS
WHAT ARE CABLE LUGS?
ELECTRICAL LUGS AND ITS VARIOUS APPLICATIONS
PURCHASE EFFICIENT ELECTRICAL LUGS FROM THE BEST COMPANIES
COPPER CABLE LUGS
COPPER LUGS
DESCRIPTION:
APPLICATION:
ALUMINIUM CABLE LUGS
USES AND APPLICATION
THE MAIN AREAS OF APPLICATION INCLUDE:
TYPE OF TERMINALS APPLICATION
APPLICATION OF TUBULAR COMPRESSION CABLE LUG
FIELD OF APPLICATIONS
B.I.S. SPECIFICATION
MARKET POSITION
GOVT. INITIATIVES TO BOOST CABLE INDUSTRY IN INDIA
RECOMMENDED BY COLOMBIA
MAJOR COMPANIES
SPECIFICATIONS OF CABLE LUGS
MANUFACTURERS/SUPPLIERS OF CABLE LUG
PROCESS FLOW CHART
FABRICATION PROCESS OF LUG
1. RAW MATERIAL
THE TERMINALS ARE MANUFACTURED FROM RAW MATERIAL AS FOLLOWS:
2. FABRICATION
STAGES OF MANUFACTURING PROCESS OF TUBULAR CABLE LUGS
QUALITY CONTROL
A. RAW MATERIAL
B. FINISHED MATERIAL
C. PROCESS INSPECTION
TESTING
(A) TYPE TEST:
A) ELECTRICAL RESISTANCE TEST
B) TEMPERATURE TEST
ROUTINE TEST:
1) DIMENSIONAL ANALYSIS
2) ELECTRICAL CONDUCTIVITY TEST
3) SURFACE FINISH
4) FLATTENING TEST
MARKING
SUPPLIERS OF RAW MATERIALS
ALUMINIUM TUBE
COPPER TUBE
PICKLING CHEMICALS
TIN INGOT
SUPPLIERS OF PLANT AND EQUIPMENTS
PIPE CUTTING MACHINE
CNC TURRET PUNCH PRESS AND CNC PRESS BREAK
CNC PRESS
PUNCHING PRESS
POWER PRESS
BENDING MACHINE
MECHANICAL PRESS
CNC PLASMA CUTTING MACHINE
CNC SHEET BENDING MACHINE
CNC PUNCHING PRESS
DRILLING MACHINE
POWER HACKSAW
GRINDING MACHINE
TIN PLATING PLANT
POWER TRANSFORMERS
ELECTRICAL PANEL
COOLING TOWER
EFFULENT TREATMENT PLANT
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SHOT BLASTING MACHINE
JIGS AND FIXTURE
SUBMERSIBLE WATER PUMP
PRINCIPLES OF PLANT LAYOUT
SOME OF THE FACTORS IN RAIL-TRACK PLANNING ARE:
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
DEPRECIATION:
FIXED ASSETS:
WORKING CAPITAL:
BREAK-EVEN POINT:
OTHER FIXED EXPENSES:
MARGIN MONEY:
TERM LOANS:
TOTAL LOAD:
LAND AREA/MAN POWER RATIO:
MANPOWER
GENERAL
BASIS OF ESTIMATION
UTILITIES
UTILITIES
POWER
WORKING
TOTAL MANPOWER AND PAYROLL
SWOL ANALYSIS
STRENGTHS
OPPORTUNITIES
WEAKNESS
LIMITATIONS
PLANT LAYOUT
PLANT LOCATION
GEOGRAPHY
ORGANIZATION CHART
IMPLEMENTATION SCHEDULE
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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