Detailed Project Report on Cable Lugs Manufacturing (Copper & Aluminium)

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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

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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