What are the data references for One Hole Long Barrel Copper Lug?

In the crucial field of electrical connections, the One Hole Long Barrel Copper Lug plays a prominent role. The various data of it are the core basis for accurate selection and safe application. It is of great significance to explore these data in depth.

I. Detailed Analysis of Dimension Data
(I) Key Points of Bore Diameter Specifications
Standard Size Series: Common bore diameters include specifications such as 6mm, 8mm, and 10mm. The accurate bore diameter determines the diameter of the bolts or studs it can be matched with. For example, a 6mm bore diameter is suitable for an M6 bolt, ensuring a tight connection and avoiding connection looseness or poor contact caused by mismatches between the bore diameter and the bolt.
Tolerance Range Consideration: The bore diameter usually has strict tolerance control, generally ranging from ±0.1mm to ±0.2mm. This small tolerance range ensures that during mass production and installation, each terminal can be precisely matched with corresponding connecting parts, maintaining the consistency and stability of electrical connections.
(II) Key Points of Barrel Length Dimension
Different Application Barrel Lengths: Depending on the usage scenarios, the barrel length varies. In general distribution box connections, the barrel length may be between 20mm and 30mm. For scenarios with higher requirements for connection reliability, such as high-voltage cable connections, the barrel length can reach 50mm or even longer. A longer barrel length can increase the contact area between the wire and the terminal, reducing the contact resistance.
Relationship between Barrel Length and Current: There is a certain correlation between the barrel length and the current that can be carried. Generally, the longer the barrel length, the relatively better the heat dissipation effect. Under the same material and wire diameter conditions, a larger current can be allowed to pass through. For example, a terminal with a barrel length of 30mm may carry 20% - 30% more current than a terminal with a barrel length of 20mm under a specific wire diameter.

II. Interpretation of Electrical Performance Data
(I) Rated Current Parameters
Basis for Current Classification: The rated current has clear classifications, such as 100A, 200A, and 400A. This is determined based on multiple factors such as the material of the terminal, heat dissipation conditions, and contact area. For example, a terminal made of high-purity copper with a longer barrel length and good contact will have a higher rated current rating to meet the connection needs of electrical equipment with different powers.
Derating Rules in Practical Application: In practical applications, if the environmental temperature is high, heat dissipation is poor, or the diameter of the connecting wire is smaller than the recommended value, the rated current needs to be derated. Generally, for every 10°C increase in the environmental temperature, the rated current may need to be reduced by 10% - 15% to ensure that the terminal works within a safe range and prevent overheating damage.
(II) Contact Resistance Values
Ideal Resistance Range: High-quality One Hole Long Barrel Copper Lug usually has a contact resistance in the micro-ohm level, such as 50 micro-ohms to 200 micro-ohms. Low contact resistance can reduce power loss at the connection point, lower the risk of heat generation, and improve the efficiency of the electrical system. For example, in high-power transmission circuits, low contact resistance can effectively reduce line losses and save energy.
Factors Affecting Resistance: Contact resistance is affected by factors such as surface roughness, contact pressure, and the presence of oxide layers. When the terminal surface is smoother, the contact pressure is greater, and there is no oxide layer, the contact resistance is smaller. During the installation process, using appropriate wire crimping tools to ensure sufficient contact pressure can effectively reduce the contact resistance.

III. Explanation of Material Property Data
(I) Influence of Copper Purity
Purity and Conductivity: Generally, electrolytic copper with a purity of over 99.9% is used. High-purity copper has excellent electrical conductivity with high electrical conductivity, enabling efficient current transmission in the terminal. Compared with low-purity copper, it can reduce the resistance by about 10% - 20% and reduce power loss, improving the overall performance of the electrical system.
Purity and Corrosion Resistance: High-purity copper also has relatively good corrosion resistance to a certain extent. In a humid or slightly chemically polluted environment, it can slow down the oxidation speed and prolong the service life of the terminal. However, in a harsh chemical environment, additional anti-corrosion measures may still be required.
(II) Mechanical Property Data
Hardness Index: The hardness of the copper terminal is generally between HB60 and HB90. Appropriate hardness ensures that the terminal will not deform due to being too soft during the installation process, nor will it damage the wire due to being too hard. For example, during the wire crimping operation, a terminal with moderate hardness can firmly clamp the wire, ensuring connection reliability.
Tensile Strength: The tensile strength is usually between 200MPa and 300MPa. This index determines the tolerance ability of the terminal when subjected to the tensile force of the wire. In practical applications, such as the connection of outdoor overhead lines, the terminal needs to have sufficient tensile strength to prevent the separation of the terminal and the wire under the action of wind load, self-weight and other tensile forces.

IV. Q&A Session
(I) Question: How to choose the appropriate terminal bore diameter according to the actual current?
Answer: First, determine the actual current size, then refer to the terminal product manual to find the terminal specification corresponding to the rated current. The recommended bore diameter is the appropriate choice. Meanwhile, the impact of environmental factors on the current carrying capacity should also be considered.
(II) Question: What should be done if the contact resistance is too large?
Answer: First, check whether there is an oxide layer at the connection part. If so, clean it. Then check whether the contact pressure is sufficient and use appropriate tools to increase the pressure. If it is still not satisfactory, it may be necessary to replace the terminal or check whether the wire diameter is matched.Answer: First, check whether there is an oxide layer at the connection part. If so, clean it. Then check whether the contact pressure is sufficient and use appropriate tools to increase the pressure. If it is still not satisfactory, it may be necessary to replace the terminal or check whether the wire diameter is matched.

V. Process Steps for Data Application
(I) Determination of Selection Data
Evaluation of Current Requirements: Calculate the required current size according to the power and working voltage of the electrical equipment, considering a certain margin, and determine the approximate rated current requirement.
Selection of Size Adaptation: Select the appropriate bore diameter and barrel length according to the diameter of the connecting wire and the connection method. Ensure that the wire can be inserted into the terminal smoothly and that there is sufficient contact area and mechanical stability after connection.

(II) Guarantee of Installation Data
Pressure Control: Use professional wire crimping tools and perform the wire crimping operation according to the pressure value recommended by the terminal manufacturer to ensure that the contact pressure is within an appropriate range to obtain a good contact resistance.
Torque Setting: For terminals connected by bolts, set an appropriate torque value according to the bolt specification and the terminal material to ensure a firm connection and avoid damaging the terminal or connecting parts due to excessive tightening.

(III) Monitoring of Operation Data
Temperature Monitoring: During the operation of the terminal, use infrared thermometers and other equipment to regularly monitor the temperature of the terminal. If the temperature rises abnormally, it may indicate that the current is too large, the contact is poor, or the heat dissipation is not good, and the cause needs to be investigated in time.
Resistance Recheck: Recheck the contact resistance of the terminal at regular intervals (such as every six months or one year) using micro-ohmmeters and other instruments. If the resistance increases beyond the allowable range, corresponding improvement measures need to be taken.

VI. Summary
The data references for the One Hole Long Barrel Copper Lug cover multiple aspects such as dimensions, electrical performance, and material properties. Through in-depth understanding of these data, reasonable application processes, and the problem-solving ideas in the Q&A session, accurate selection, correct operation, and effective monitoring can be achieved in the design, installation, and operation and maintenance of electrical connections, ensuring the safe, efficient, and stable operation of electrical systems and giving full play to the important role of this terminal in the electrical field.