Heavy Duty Tinned Copper Ferrules: Purpose, Uses and Key Benefits

In heavy duty electrical networks, safety and efficiency are of utmost importance. A considerable number of accessories are used in wires and power cables for proper flow of current while maintaining longevity of cable and negating the risk of hazards. One such accessory is Ferrule.

What is Ferrule?

In simple terms, ferrule is a deformable long ring or short tube like structure made of highly conductive material, primarily copper or aluminum. It used to terminate open stranded wire or join them with connector, preventing the strands from fraying or spreading out. This helps secure connection by reducing contact resistance within wire strands, maximising contact area and therefore increasing efficiency of flow of current, reducing risk of overheating and short circuits. It is insulated with polypropylene to provide protection and easy installation.

How is Ferrule Installed?

Conductor wire is cut sharply, without jagged edges of strips.

Insulation is removed of measured length only. Strip length should be nearly equal to barrel length of ferrule.

Insert the stripped wire into the ferrule

Crimp the ferrule with proper crimping tool

Perform pull force test to check correct alignment

Uses of Heavy Duty Tinned Copper Ferrule

Heavy duty industrial usage of ferrules demands high performance with durability.  To meet these demands, companies design and produce heavy duty ferrules. Heavy Duty Tinned Copper Ferrules by Yamuna Cable Accessories is a product specially designed for this purpose. The tin coating over copper provides excellent resistance to corrosion and abrasion which is a crucial factor in industries. It is particularly useful in contaminant-prone environments such as marine, offshore and chemical processing plants or high stress electrical systems such as control panels, aviation, power generation, heavy machinery etc. Key objectives of heavy duty ferrules include:

1. Managing high voltage loads in large diameter strands in transformers, switchgears, industrial motors without overheating and degrading.
2. Tin coating for high mechanical strength to ensure long durability and strain relief.
3. Air-tight connection between wire strands and prevention of oxidation.
4. In high stress environments where vibration, temperature, motion goes to extreme levels.
5. Prevention of high temperature, short circuits and arc flashes.
6. Avoid potential risk of open conductor wire and fraying of uninsulated wire.
7. Preventing downtimes which can be costly in manufacturing industries, power grids, transmission systems.
8. Complete consolidation of strands to ensure high conductivity through terminals or connectors.
9. Neat and organised termination in industrial settings. This makes sure ease of inspection, testing and maintenance.
10. Ease of overall operations, maintain integrity of complex electrical networks over long periods of continuous load.

High Performance, secure connections over a long period of high load on cables is possible due to high quality of copper and tin, high conductivity and wide varieties of ferrules that are available to meet diverse needs of the electrical network. Yamuna Cable Accessories excels at delivering heavy duty ferrules to a wide clientbase across the world. These ferrules have optimal conductivity of 99.9%, available in a wide range from 2.5 sqm to 1000 sqm and are certified by International Annealed Copper Standard (IACS).