Detailed Project Report on cable lugs manufacturing aluminium and copper

CABLE LUGS MANUFACTURING
(ALUMINIUM AND COPPER)
[CODE NO.3382]  


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.

The words "cable" and "wire" are sometimes mistakenly interchanged. Cables are made from multiple wire strands, while wires consist of a single strand. Both cables and wires may be used with cable lugs of a suitable type.

One end of a cable lug is typically used for connecting a cable, which could be soldered, welded, or crimped depending on the type. The connection end of the lug is then fastened to a matching terminal or connection point by means of a bolt, screw, or spring clip. Numerous sizes, configurations, and material types typically are available to suit particular applications, but metal is the predominate material used. A cable lug is sometimes called a "cable connector" or "cable anchor," depending on industry jargon and application.

The connector end of a cable lug is typically chosen for its compatibility to the terminal type or anchoring method. Fork or U-shaped lugs are used for screw terminals; closed-ring or O-type lugs are used for bolt-on applications; and pin or spade lugs are used for press-on pin or blade 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.

Lug is A connecting device with barrel accommodating respective conductor size of electrical cable and which has a fixing arrangement of termination by means of a bolt fixing or pin-insertion in tunnel type terminal blocks and screwing.

Cable lugs, also referred to as Cable terminal ends or cable shoes are electrical supplies utilized to securely connect or terminate cables to electrical devices, power or control panels, junction boxes, equipments and machineries. These lugs are often used to join power cables together as well. Cable Lugs intended to ensure the safety of both the appliances and human beings. These lugs can be uniquely engineered according to the client’s preferences and requirements.


COST ESTIMATION

Plant  Capacity                                               :    400.00 Kg./day
land & Building (500 Sq.Mtr)                        :    Rs. 84.50 Lacs
Plant & Machinery                                           :    Rs. 28.95 Lacs
Working Capital for 2 Months                        :    Rs. 1.07  Cr
Total Capital Investment                                 :    Rs. 2.34  Cr
Rate of Return                                                  :    33%
Break Even Point                                              :    55%


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    
TYPE OF TERMINALS APPLICATION    
APPLICATION OF TUBULAR COMPRESSION CABLE LUG    
FIELD OF APPLICATIONS    
B.I.S. SPECIFICATION    
MARKET SURVEY    
GOVT. INITIATIVES TO BOOST CABLE INDUSTRY IN INDIA    
RECOMMENDED BY COLOMBIA    
SOME OF THE MAJOR COMPANIES IN THE INDUSTRY INCLUDE –    
FUTURE OUTLOOK INDIA WIRES AND CABLES MARKET 2015-2019    
EXPORT DATA OF CABLE LUGS    
SPECIFICATIONS OF CABLE LUGS    
MANUFACTURERS/SUPPLIERS OF CABLE LUG    
PROCESS FLOW CHART    
FABRICATION PROCESS OF LUG    
1. RAW MATERIAL    
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    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
ALUMINIUM TUBE    
COPPER TUBE    
PICKLING CHEMICALS    
TIN INGOT    
SUPPLIERS OIF 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 HACSAW    
GRINDING MACHINE    
TIN PLATING PLANT    
POWER TRANSFORMERS    
ELECTRICAL PANEL    
COOLING TOWER    
EFFULENT TREATMENT PLANT    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
SHOT BLASTING MACHINE    
JIGS AND FIXTURE    
SUBMERSIBLE WATER PUMP    


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET