Terminals, Lugs & Ferrules

When a perfect connection is required, you’ll need to use lugs, ferrules, and wire terminals. Whether you’re splicing electrical wires, or you only have one terminating conductor and one mechanical connection, you’ll want to ensure it’s made correctly. By using the highest quality equipment, you’ll safeguard your electrical system against the risk of fire or shock. Not only will it help create a safe and reliable electrical circuit, but a safe residential or working environment too.

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What are terminals, lugs, and ferrules?

In order for there to be a flow of electricity, there needs to be an unbroken circuit, and using the correct terminal connectors, lugs, and ferrules will ensure you have a safe and functioning electrical circuit.

Wire terminals

Wire terminals are a type of connector mounted onto a wire, which allow an electrical current from a power or grounding source to transfer to a device. They are crimped or soldered onto the component. Crimp terminals, like splices, provide a quick and easy connection, without the need for soldering.

Lugs

Lugs are used for connecting cables and wires to electrical appliances, other cables, surfaces, or mechanisms, in both domestic and industrial environments. Designed to be easily installed and removed for repairs or maintenance, lugs are generally used when permanent, direct-fastening methods aren’t feasible or necessary. Many types of lugs have a safety covering to avoid shocks or damage to wiring.

Ferrules

Protecting the fine strands of wire from straying, ferrules help ensure a stronger current. Once the wire is inserted into the ferrules, the ferrules are then inserted into the terminal compartment to be crimped onto the wire. They are used in countless industries where power distribution and connections are needed and are frequently used with screw type terminal blocks.

Are there different types of terminals, lugs, and ferrules?

There are many different types of terminals, lugs, and ferrules, depending on the job they are required to do. When purchasing specific electronic equipment, make sure that your purchase meets industry standards and project requirements.

What are the different types of wire terminals?

Ring terminals

Ring terminals have a round head that easily allows a screw or stud to be attached. Often used in the automotive industry to connect mechanical relays to engines, ring wire terminals can also be called ring connectors and are available in a variety of sizes. It is crucial that the ring terminal is compatible with the wire gauge and stud size. Ring terminals are either crimped or soldered to the wire and are available insulated or non-insulated.

Spade terminals

Also called fork terminals, spade terminals are so called because of the shape of the terminal. Spade terminals are available in a variety of sizes, depending on the gauge of the wire and stud size. The open-end of the spade terminal makes it convenient to use, allowing for easy attachment or removal from the screw. Spade terminals are especially beneficial for projects that are tight on space for installation. They are available insulated or non-insulated.

Hook terminals

Similar to a spade terminal, hook terminals are convenient to use thanks to their open-ended hook shape. They offer a simplistic yet durable connection for a variety of projects.

Quick-disconnect terminals

Quick-disconnect wire terminals are reliable and convenient to use. They can easily connect and disconnect two wires, and are commonly found in industrial machinery, cars, and consumer products, such as dishwashers, and microwave ovens. Delivering a stable and durable connection, they are available insulated or non-insulated.

Bullet terminals

Also called bullet connectors, bullet wire terminals provide a reliable and secure connection. Bullet terminals connect with male and female connectors to create a high-quality connection. Bullet terminals help prevent corrosion and other potentially harmful materials from entering a wire harness. They are often used in automobile connections.

Butt terminals

Connecting or terminating single or multiple wires, butt terminals help prevent abrasion and cutting. The extra protection offered by butt terminals helps keep moisture, corrosion, and other negative elements away from the exposed wires. Thanks to their ability to mate and connect wires with ease, they offer a simple solution when time is of the essence. Simply install each wire on the open end of the connector, then crimp both ends of the terminal to secure the connection.

Flag terminals

Flag terminals, or flag connectors, offer a secure and convenient connection. Working well in tight spaces, they’re also a good choice when quick-disconnect wire terminals are too large. They are available in insulated and non-insulated, providing a quick and easy connection.

What are the different types of lugs?

Compression lugs

Compression lugs are designed for solid, stranded, fine stranded, and finest stranded copper conductors, and cables. The markings on the lugs refer to the information regarding the origin and application, as well as the number of required crimps. They are used for telecommunications equipment, transformers, and welding equipment among others.

Standard tubular lugs

Made from electrolytic copper, standard tubular lugs tend to be shorter than compression lugs, and also differ in tube dimensions. To ensure a secure and complete connection, a cable crimping tool should be used. If not, it may result in increased joint resistance, increased temperatures, and even fire.

Solderless terminals

Solderless terminals are used for cable terminations, and they connect, terminate, or crimp round multi, fine, and superfine stranded conductors. Used in panel building and control cabinet manufacturing, solderless terminals are made from copper sheets.

What are the different types of ferrules?

Uninsulated ferrules

Uninsulated ferrules are available without the plastic shoulder. The non-shouldered or uninsulated ferrules are useful when termination space is tight or where a shoulder would obstruct an adjacent terminal.

Insulated single conductor ferrules

Insulated single conductor ferrules are easy to work with, especially on smaller conductors where the shoulder helps to guide wire strands to the ferrule pin. Without the shoulder, uninsulated ferrules can be like threading a needle, with any lose wires reducing the strength of the connection.

Twin wire ferrules

Twin, dual, or double-wire ferrules are useful when you need to wire two conductors into one terminal – often seen when creating a common supply to push button switches in industrial panels. In a residential setting, they are handy to connect multiple terminals within heating or lighting controls. Twin ferrules are available insulated or uninsulated. Insulated ferrules have an oval-shaped shoulder to accommodate two conductors.

Why choose RS for your terminals, lugs, and ferrules?

As one of North America’s leading industrial suppliers, we stock top manufacturers, including TE Connectivity, American Electrical, Inc., and Molex Incorporated. Our range of electronic and industrial equipment meets the highest industry standards of performance and safety to help you create a secure and efficient environment.

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