Battery Terminal Lugs

Suppose you need lugs that ensure steady power and meet tough industry standards for battery systems. Our Battery Terminal Lugs tackle key pain points in electrical setups, delivering solutions that boost safety, strength, and performance.

Material Composition

Lead-antimony alloy (PbSb2) or tinned copper (C11000) with corrosion-resistant plating

Conductor Size Range

6 mm² to 120 mm² (AWG 10 to 250 kcmil)

Current Carrying Capacity

50 A to 600 A (continuous DC, 40°C ambient)

Dimensions

Terminal width: 15-45 mm; Stud size: M6-M12; Height: 25-60 mm

Weight

80 g to 500 g (vibration-resistant designs)

Product Description

Our lugs are built to keep current flowing strong and safe to your batteries. Using lead-antimony alloy or tinned copper, these lugs cut resistance, ensuring solid power delivery even in harsh conditions. This lifts battery efficiency and keeps your systems working without fail.

Barrel Length

20-50 mm (1.5× conductor diameter)

Termination Type

Compression barrel + threaded stud (SAE/JIS standards)

Crimping Compatibility

Hydraulic crimping (15-60 kN) or hammer-style battery crimpers

Operating Temperature Range

-40°C to +105°C (lead alloy) / -40°C to +120°C (copper)

Surface Finish

Tin plating (standard) or silver plating (high-performance)

Voltage Rating

Up to 48V DC (UL 486A tested)

Tensile Strength

55 MPa (lead alloy) / 220 MPa (copper)

Environmental Resistance

500-hour salt spray (ASTM B117), acid-resistant for battery environments

Standards Compliance

SAE J378, UL 486A, IEC 60352-2

Installation Method

Crimping + torque-controlled stud tightening (5-25 Nm)

Conductor Compatibility

Stranded copper (Class B/K) or battery cable (SAE J1127)

Technical Advantages

Battery setups often deal with corrosion, especially near acid or salt. Our Battery Terminal Lugs use tin plating and a compression barrel to stay tough in rough spots without losing hold.

Quick installs matter when production lines move fast. Our lugs work with hydraulic crimping and stud torque stability, making setup fast and firm with no slips.

Let's Get Started

Need reliable Lugs for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Industry Applications

Electric Vehicle Battery Packs

Handles 600A continuous current in fast-charging systems, with M12 studs that pflegen torque under 10G vibration (SAE J378 tested).

Energy Storage Systems

Silver-plated copper versions prevent galvanic corrosion in 48V lithium-ion banks, with flame-retardant insulation (UL 94V-0).

Marine Starting Systems

Lead-antimony alloy resists saltwater corrosion, surviving 1000+ wet/dry cycles in offshore environments.

Industrial UPS Backup

Serrated barrel interior grips cables securely, preventing pull-out during 2000A fault currents (IEC 60947-1 verified).

Telecom Power Cabinets

Compact 25mm height fits tight spaces in 5G battery backups, with tin plating that resists sulfur corrosion.

Motive Power Equipment

Reinforced 500g design withstands daily impacts in forklift and AGV battery swaps.

Vibration Resistance for Seamless Performance

Each battery system needs lugs that fit its design to avoid setup troubles. Our Battery Terminal Lugs carry big current and lock onto studs tight, cutting install time and mistakes.

Heavy shaking can loosen wires and cut power over time. Our lugs feature strong tensile strength and crimp seal longevity, keeping connections steady in bumpy setups like vehicles or machines.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

What cost savings can we expect by switching to your battery lugs compared to standard terminals?

While the initial investment is slightly higher, our lugs reduce long-term costs by eliminating corrosion-related replacements – field data shows 3x longer service life in lead-acid applications. We also offer volume discounts for orders above 500 units, with documented cases where fleet operators saved 22% annually on maintenance. The integrated torque stripe further reduces labor time by 30% per installation.

How does the lead-antimony alloy outperform brass or copper in battery applications?

The PbSb2 alloy chemically matches lead-acid battery posts, preventing galvanic corrosion that causes voltage drops in brass/copper terminals. Testing shows 0.02mV/year resistance increase versus 0.15mV for brass after 500 salt spray hours (ASTM B117). The alloy’s 55MPa tensile strength also resists cracking during thermal cycling (-40°C to +105°C).

How do you ensure supply chain continuity for high-volume orders?

We pflegen 6 months of strategic raw material stock (lead/copper billets) at all times, with dual-source suppliers for plating chemicals. Orders above 10,000 units come with a 100% on-time delivery guarantee, backed by real-time production tracking. Our ISO 9001-certified factories have maintained 99.6% fulfillment rates for 5+ years.

Do you provide custom branding or packaging for OEM partners?

Yes, we offer laser-etched part numbers, company logos, and color-coded insulation for easy identification in production lines. Our kitting service can include custom foam inserts or bulk packaging tailored to your assembly process, with no minimum order quantity for branded solutions.

Can these lugs handle the high inrush currents of EV fast charging?

Absolutely! The tinned copper version supports 2000A inrush for 10 seconds (IEC 60947-1 tested) without degradation. The serrated barrel design maintains grip on cable strands even under rapid thermal expansion, a critical advantage for 400V+ DC fast charging systems.

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LOCATIONS

Sitz

10-A, First Floor, V. V Komplex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, Indien.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti Coimbatore-641035, Tamil Nadu, Indien. ㅤ

Battery Terminal Lugs

Material Composition

Conductor Size Range

Current Carrying Capacity

Dimensions

Weight

Product Description

Barrel Length

Termination Type

Crimping Compatibility

Operating Temperature Range

Surface Finish

Voltage Rating

Tensile Strength

Environmental Resistance

Standards Compliance

Installation Method

Conductor Compatibility

Technical Advantages

Let's Get Started

Industry Applications

Vibration Resistance for Seamless Performance

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Having Doubts? Our FAQ

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Weitere Standorte

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Battery Terminal Lugs

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Battery Terminal Lugs

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