Supplied in packages of copper or aluminum tubing, reel or rod.
Length sizing is made in accordance with the standards. Countersink is opened into the pipe.
Sizing and Countersinking in Classical Production
(Machining waste is given 3-4 mm per piece)
The number of parts produced per day of the work machine used
1 saw with 1 staff (1.000-3.000 pieces / day)
With 1 Lathe or Automat (1.000-3.000 pieces / day)
For cutting with a manual saw and countersinking, a machining machine such as a classic lathe-automat-drill should be used.
Two personnel work on these two machines and 1,000-3,000 cable lugs can prepare semi-finished products per day.
Sawdust up to the thickness of the saw blade (3-4 mm) is scrap.
2 staff + 2 machines,
Machining waste up to the thickness of the saw blade,
1,000 - 3,000 pieces / day
Fully Automatic Sizing and Countersinking
(No Machining Waste. Orbital Cutting)
The number of parts produced per day of the work machine used
For double lugs with 1 C & CSM (10.000-15.000 pcs / day = 15.000-30.000 Semi-finished products for cable lugs)
Since orbital cutting is made with rotating blades, there is no chip formation for cutting, cutting is done without waste.
-For our fully automatic molds that produce two cable lugs from one pipe, the two ends of the pipe are countersinked at the same time.
Production time for a cable lug is 1.5 seconds total for cutting and countersinking.
In this case, a semi-finished product of cable lugs is prepared between 10.000 and 20.000 per day.
6-16 mm Copper and Aluminum Pipe Orbital Cutting - Double Sided Countersink
16-45 mm Copper and Aluminum Pipe Orbital Cutting - Double Sided Countersink
Without personnel,
without waste
10.000- 20.000 pieces / day
There are 100 types of cable lugs, which is a special product made of copper pipes.
It is possible to produce this labor-intensive product with fully automatic machines. Classical method and fully automatic production differences are explained below.
Open die and mechanical eccentric press:
Eccentric press + End crushing mold + One staff
Eccentric press + Punching and marking mold + one staff
Since one piece is produced in each operation, the capacity is low. (1.000-5000 pieces of production are made with 2 presses and 2 personnel per day.)
The tip cut depends on the leaning distance.
It can be even more than desired.
The cut scrap is big as pictured.
Semi-automatic hydraulic turntable:
Special production hydraulic machine (3 hydraulic heads)
3 molds for each model
End crushing station + Screw hole punching station + Brand and model name writing form mold
Since one piece is produced in each operation, that is, a single piece of cable lug is taken from the semi-finished pipe, the cutting scrap is large as in the picture. Production capacity is low, cutting scrap is high.
The hydraulic press works slowly. Production is slow at this rate. 5.000-6.000 pieces / day production is made with a staff.
China Origin Fully automatic mold review:
The workmanship and technical life of the Chinese mold is far from CE expectations.
It is obvious that the female sockets given in the picture below are very thin sections, very close to the edge and will break in a few thousand presses.
Quality and mold life may not meet expectations.
A Kalıp
Fully automatic cable lug molds
You get our molds and machines at a higher price than the Chinese manufacturer. However, molds and machines in CE standards are guaranteed for 2 years, excluding usage errors. When the defective part is sent, it is replaced with the new part in return.
A parts list and user maintenance manual are given with our machines and molds.
Fully automatic Vibro Transfer Molds that you can work by connecting to your existing mechanical eccentric presses:
-30.000 Pieces / Day
-30% less cutting loss compared to other methods
Machines and molds produced by A Kalıp are in compliance with E4.0.
You can monitor your mobile phone or any computer with the central control panel. You can contact your business with the current MRP and get a historical report. The raw material loaded, the number of cable lugs and the total scrap account map in the production area can be updated at any time.
Material Preparation (Sizing and Countersinking on Both Ends of the Pipe
Mechanical strain (with Mechanical Press and dies)
Fully Automatic
Cable Lug Molds
Fully Automatic
Copper Pipe Cutting and Two End Flaring Machine
Fully Automatic Rotary Table
Special Hydraulic Press
Fully Automatic Progressive
Terminal Connector Molds
Medya
COMPARISON OF CABLE LUGS MANUFACTURING METHODS:
A-KLP is a boutique family company that developing products at the request of customers since 1947 under our family name AKŞİT.
We manufacture manual, semi-automatic, and fully automatic machines and molds in response to the needs of our customers all over the world.
.
Research and Development, Industrial Product,
Method Development and Designer
It is a Machinery and Mold Production Center.
A KLP Design Machinery Trade Ltd.
ESENYURT VD. 00 1215 2214
ISTANBUL CHAMBER OF COMMERCE 300767/5
Akçaburgaz District Alkop Industrial Site A2 Block No:6
Postal Code 34522 Esenyurt
Istanbul/TR
+90 551 551 2508
+90 850 532 531 1
info@a-klp.com
We design and manufacture special-purpose functional tools, machines and products.
We produce under prototype and mass production conditions in our design and production workshop.
All of the work machines used in the production of cable lugs are designed and produced by us.
We have been making Manual molds, Prograsiv automatic molds and transfer molds since 1947.
We design and manufacture machines that will make production unmanned, less wastage and faster by making the operations required by the production line a single special-purpose machine.
For the production of cable lugs; from semi-finished product preparation to press production, all gathered on a single line.
You can produce one cable lug per second by combining the Unmanned Orbital copper / aluminum pipe cutting and chamfering process with a fully automatic vibro transfer die.
You can review our products from the catalog in our whatsapp business account.
I added the video links about the cable lug production tools to the Whatsapp Catalogue.
Please send a message for the price list and general brochure.
+90 551 551 2508 or info@a-klp.com
Go to the link below to review the catalog on WhatsApp: https://wa.me/c/905515512508
BROSURLER
Supplied in packages of copper or aluminum tubing, reel or rod.
Length sizing is made in accordance with the standards. Countersink is opened into the pipe.
Sizing and Countersinking in Classical Production
(Machining waste is given 3-4 mm per piece)
The number of parts produced per day of the work machine used
1 saw with 1 staff (1.000-3.000 pieces / day)
With 1 Lathe or Automat (1.000-3.000 pieces / day)
For cutting with a manual saw and countersinking, a machining machine such as a classic lathe-automat-drill should be used.
Two personnel work on these two machines and 1,000-3,000 cable lugs can prepare semi-finished products per day.
Sawdust up to the thickness of the saw blade (3-4 mm) is scrap.
2 staff + 2 machines,
Machining waste up to the thickness of the saw blade,
1,000 - 3,000 pieces / day
Fully Automatic Sizing and Countersinking
(No Machining Waste. Orbital Cutting)
The number of parts produced per day of the work machine used
For double lugs with 1 C & CSM (10.000-15.000 pcs / day = 15.000-30.000 Semi-finished products for cable lugs)
Since orbital cutting is made with rotating blades, there is no chip formation for cutting, cutting is done without waste.
-For our fully automatic molds that produce two cable lugs from one pipe, the two ends of the pipe are countersinked at the same time.
Production time for a cable lug is 1.5 seconds total for cutting and countersinking.
In this case, a semi-finished product of cable lugs is prepared between 10.000 and 20.000 per day.
6-16 mm Copper and Aluminum Pipe Orbital Cutting - Double Sided Countersink
16-45 mm Copper and Aluminum Pipe Orbital Cutting - Double Sided Countersink
Without personnel,
without waste
10.000- 20.000 pieces / day
There are 100 types of cable lugs, which is a special product made of copper pipes.
It is possible to produce this labor-intensive product with fully automatic machines. Classical method and fully automatic production differences are explained below.
Open die and mechanical eccentric press:
Eccentric press + End crushing mold + One staff
Eccentric press + Punching and marking mold + one staff
Since one piece is produced in each operation, the capacity is low. (1.000-5000 pieces of production are made with 2 presses and 2 personnel per day.)
The tip cut depends on the leaning distance.
It can be even more than desired.
The cut scrap is big as pictured.
Semi-automatic hydraulic turntable:
Special production hydraulic machine (3 hydraulic heads)
3 molds for each model
End crushing station + Screw hole punching station + Brand and model name writing form mold
Since one piece is produced in each operation, that is, a single piece of cable lug is taken from the semi-finished pipe, the cutting scrap is large as in the picture. Production capacity is low, cutting scrap is high.
The hydraulic press works slowly. Production is slow at this rate. 5.000-6.000 pieces / day production is made with a staff.
China Origin Fully automatic mold review:
The workmanship and technical life of the Chinese mold is far from CE expectations.
It is obvious that the female sockets given in the picture below are very thin sections, very close to the edge and will break in a few thousand presses.
Quality and mold life may not meet expectations.
A Kalıp
Fully automatic cable lug molds
You get our molds and machines at a higher price than the Chinese manufacturer. However, molds and machines in CE standards are guaranteed for 2 years, excluding usage errors. When the defective part is sent, it is replaced with the new part in return.
A parts list and user maintenance manual are given with our machines and molds.
Fully automatic Vibro Transfer Molds that you can work by connecting to your existing mechanical eccentric presses:
-30.000 Pieces / Day
-30% less cutting loss compared to other methods
Machines and molds produced by A Kalıp are in compliance with E4.0.
You can monitor your mobile phone or any computer with the central control panel. You can contact your business with the current MRP and get a historical report. The raw material loaded, the number of cable lugs and the total scrap account map in the production area can be updated at any time.
Material Preparation (Sizing and Countersinking on Both Ends of the Pipe
Mechanical strain (with Mechanical Press and dies)
Fully Automatic
Cable Lug Molds
Fully Automatic
Copper Pipe Cutting and Two End Flaring Machine
Fully Automatic Rotary Table
Special Hydraulic Press
Fully Automatic Progressive
Terminal Connector Molds
FAQ
COMPARISON OF CABLE LUGS MANUFACTURING METHODS:
You can review our products from the catalog in our whatsapp business account.
I added the video links about the cable lug production tools to the Whatsapp Catalogue.
Please send a message for the price list and general brochure.
+90 551 551 2508 or info@a-klp.com
Go to the link below to review the catalog on WhatsApp: https://wa.me/c/905515512508
Which machines and molds in the brochure should we buy?
You must order a different mold for each different part in your production plan.
It is important for production optimization that you determine your choice between the molds in the fully automatic, semi-automatic or manual system according to your annual production target.
What are the machines and molds required for start-up?
For Fully Automatic Production
1 – Pipe Cutting Machines (Orbital Cutting Machine)
2 - Countersinking / Butt Connector Machine: For countersinking the pipe at both ends.
3 - Eccentric Type Mechanical Press Machine : (According to cable lug dimensions: 35 tons for 6/70 mm2; 50 tons for:70/240 mm2; 120 tons for: 240/1000 mm2).
You can use your existing Eccentric Type Mechanical Press Machines but the table hammer distance of machine must 300 mm minimum.
4 - Manual or fully automatic molds for each different cable lug, common vibro boiler and PLC system box for molds. (minimum order quantity for mold is 5.)
For Semi- Automatic Production ( For One Cable Lug)
1 – Pipe Cutting Machines (Orbital Cutting Machine)
2 - Countersinking / Butt Connector Machine: For countersinking the pipe at both ends.
3 - Custom Multi-Head Rotary Table Hydraulic Type Press Machine: (According to cable lug dimensions: 35 tons for 6/120 mm2; 50 tons for: 6/400 mm2; 120 tons for: 240/1000 mm2).
4 - Mold group to be connected to Custom Multi-Head Rotary Table Hydraulic Type Press Machine for each different cable lug.
For Semi- Automatic Production (For Double Cable Lug)
1 – Pipe Cutting Machines (Orbital Cutting Machine)
2 - Countersinking / Butt Connector Machine: For countersinking the pipe at both ends.
3 - Custom Multi-Head Rotary Table Hydraulic Type Press Machine: (According to double pieces cable lug dimensions: 35 tons for 6/70 mm2; 50 tons for: 6/240 mm2; 120 tons for: 240/1000 mm2).
4 - Mold group to be connected to hydraulic type pres machine for each different cable lug.
For Manuel Production (For Double Cable Lug)
1 – Pipe Cutting Machines (Orbital Cutting Machine)
2 - Countersinking / Butt Connector Machine: For countersinking the pipe at both ends
3 - Eccentric Type Mechanical Press Machine : (According to cable lug dimensions: 35 tons for 6/70 mm2; 50 tons for:70/240 mm2; 120 tons for: 240/1000 mm2).
4 – Manual molds to be connected to Eccentric Type Mechanical Press Machine for each different cable lug.
How many cable lugs are produced with a mold?
You can produce 1 cable lug per second with fully automatic mold.
Fully automatic mold : An average of 30,000 cable lugs can be produced in 10 hours.
Semi-automatic mold: You can produce 6.000 / 10.000 lugs with Semi-automatic mold in 10 hours.
Manual mold : You can produce 5.000 / 10.000 lugs with manual mold in 10 hours.
You can produce 1 cable lug per second with fully automatic mold. A pipe piece is cut in 2 seconds with a pipe cutting machine. 2 cable lugs are produced from this cut piece.
Can different cable lugs be produced in the same mold?
We do not recommend.
Cable lugs with the same metric section and same size can be produced in the same mold for variable screw diameters.
However, for this process, some parts of the mold must be variable and these parts must be disassembled by the mold master and reassembled with new parts.
Also in addition frequent replacement of mold parts shortens the life of the mold.
When this process, which is not done by us and requires experience, is done outside of our control, these molds are out of warranty.
Bigger cable lug requires bigger mold and bigger Press Machine :
Cable Lug Dimensions Press Machine
6/35 mm2 ---------------------------- 15 tons
50/95 mm2 -------------------------- 30 tons
120/240-mm2 ------------------------ 50 tons
300/625 mm2 ------------------------ 80 tons
625/1000 mm2 ------------------------ 120 tons
Which Size Of Eccentric Type Mechanical Press Machine We Need?
Molds can be mounted on standard press machine table. But the Table-Hammer distance of the Press Machine must minimum 300 mm.
What should be the press machine table and hammer dimensions?
Consumption depends on the energy consumption of the press machine you use. Molds do not consume extra energy.
Energy consumption of Pipe cutting machine and Countersinking machine is between 2 and 5 kw/h.
What is the energy consumption of the machines to be used?
A pipe piece is cut in 2 seconds with a pipe cutting machine. 2 cable lugs are produced from this cut piece. Therefore, you can produce a cable lug in 1 second.
What is the production rate of the pipe cutting machine?
Yes
Can we make custom production with our logo?
What is the amount of Raw Material/ (waste, Scrap) generated during production?
Cut-to-length scrap/wastage: 0%. (No saw thickness. Copper cuts like paper with orbital knives. Think of it as the automation of the single-blade copper breakout method with 3 knives.)
Countersinking length difference and wastage: 0%
Press outage: 2 circles falling through the screw hole and one length wastage equal to the crushed thickness in the head of 2 cable lugs. 2-3% wastage in in the amount of all raw materials.
In the last part of the copper cut into bars and scrapped. It’s approximately 2%.
Total wastage and scrap is under 5%.
Yes, But the Table-Hammer distance of the Press Machine must minimum 300 mm.
Can we use our existing “Eccentric Type Mechanical Press Machine” with "Fully Automatic Cable Lug Machine System"?
1. The mold is carried on the press table. (it takes 1 minute)
2. Press (as 2nd picture shown) in order of 3 ports;
2.1. horn connection is connected with 2 nut screws
2.2 press hammer by moving down, the bottom plate screws are tightened under spring pressure . (it takes 2 minutes)
2.3 When the mold is in the closed position, the mold table is pulled to the press table with a screw by means of 2 steel plates. (2 min.)
2.4 Press is operated with power on. Run empty several times and rolling bearings are lubricated with thin oil. (1 min.)
2.5 A few materials are fed into the mold and distance between mold plates is reduced to zero. (1min.)
3. 24 pin plug from PLC unit connects to the slot in front of the mold. (1 min.)
4. 8 air hoses in 2 groups coming out of the PLC unit mounts on the same marked quick connector. (1min.)
5.Vibro boiler and fully automatic mold bridges are brings facing each other (distance about 2-3 mm. contactless) (1 min.)
6. Press machine is started, the flywheel starts spinning, the emergency stop button is released, The material starts to be pushed into the mold by vibration after push the green start button. When it seen by the first sensor, the process starts.
Total set-up time approximately 10-15 minutes.
Considering that the other mold is disassembled and put on the shelf in 10 minutes, the setup time is maximum 30 minutes.
Please indicate set-up time to move from on size to another
This can also be done in our method. It is very easy to print marks or texts on the barrel, as the part transfer in the mold is done by placing the shaft in the copper pipe.
On attached Picture, higher resolution 1- DIN46235 16M6 and 2. 4/0-1 AWG on UL Standards.
Cable lug marking: today we mark also the press lines on the tube part(to do so we insert a pin to the pipe for support); can it be done in your method or do you do it by printing ?
A pipe piece is countersieking in 2 seconds with a pipe cutting machine. 2 cable lugs are produced from this cut piece. Therefore, you can produce a cable lug in 1 second.
What is the production rate of the pipe countersieking machine?
A different die is required for each different cable lug.
We recommend you to buy fully automatic molds for products to be produced in large quantities, and manual molds for low-volume production.
This will reduce your investment cost.
How many molds should I buy?
The smallest accepted order is 5 moulds.
Prices vary according to cable lug types and sizes.
You will receive our offer as a proforma invoice, detailing the project total.
PLC cabinet and vibrobox price:
Eccentric System Average price of a fully automatic mold (one step, two parts):
Hydraulic system Semi-automatic die tool average price (one step per piece):
Hydraulic system Semi-automatic die tool average price (one step, two pieces):
Average price of Eccentric System Manual single mold (one step two pieces):
What are the prices of the molds to be used excluding the machines (presses, countersinking machines, pipe cutting machines)?
The answers of “Frequently Asked Questions” are theoretical. These are responses provided taking into account the practice of productions. Because the manufacture follows the requests of customers, the sizes and production quantities are variable.
Purchasing Process MAP
A-KLP Tasarım Makina Ltd. Sti. 2022 Brochure
Please share information about your high capacity machines and molds used in the production of cable lugs.
It is in the following brochures in general terms.
Please share information about your high capacity machines and molds used in the production of cable lugs.
I am a second-generation member of a family that has been manufacturing thousands of molds and machinery in Turkey since 1947.
My Personal Work Experience:
I relayed my design and production experience on dozens of major industry organizations as an engineer and senior manager, after graduating from Istanbul Technical University as an engineer.
You may see some of the images and watch the videos recorded in our workshop during the production process at the link below.
https://www.youtube.com/c/ACableLug
Despite the effect of the pandemic, I'm still manufacturing machinery and molds since 2021 in my newly established corporate business to respond to the increasing demands and send them to my customers in the domestic and international markets.
Our work is ongoing in a small but high-capacity design and production workshop at the organized industrial zone
We have the staff and equipment to produce over 5 fully automatic molds and 2 full-automatic machines per month in 2022.
The parts that constitute our 3D-designed and tested machines and molds are processed in CNC Laser, Bending Press, and CNC mills and assembled.
CNC wire erosion works are also done in our design and assembly workshop. After the casing of the machine is painted with electrostatic powder paint, the assembly process begins.
Mechanical, pneumatic, and electrical assemblies of the products are made and tested.
The sample products obtained in trial production are shipped after customer approval.
There are machinery and molds that are manufactured only upon customer requests in our workshop. The longest waiting time for approved machines and/or molds is 2 weeks.
Manufactured and approved products must be received within 2 weeks.
S. AKSIT
General manager
Terms of Sale
About Us
Purchasing Process Map:
- For detailed technical information, please contact info@a‐klp.com by e-mail or by sending a 24/7 message by calling +90 551 551 2508 using applications (whatsapp).
- Share the technical drawings and/or size tables of the products that will be produced in the mold or machine you will order.
- Our offer will be sent to you as a proforma invoice. After confirming, sign the proforma invoice sent to you and send its image to us.
- Send the advance payment detailed on the invoice via bank channel and inform us by sharing the receipt via e-mail.
- Your order will be processed when the advance payment reaches our account.
- Test production of your ready product is done in our workshop. You can watch it live in our workshop. Samples from test production are sent to you and your evaluation/approval is awaited.
- With your approval, the products are made ready for shipment and the delivery is made regarding the realization of the balance payment.
You can review our products from the catalog in our whatsapp business account.
I added the video links about the cable lug production tools to the Whatsapp Catalogue.
Please send a message for the price list and general brochure.
+90 551 551 2508 or info@a-klp.com
Go to the link below to review the catalog on WhatsApp: https://wa.me/c/905515512508
Uretim Sirketi Cable Terminal Ends
A-KLP.com
UScte.com
who are we
Our design and production experience from 1947 to this day, we started to ship molds and machines abroad after 2020 ...
It is proud to supply 100% Turkish products to foreign customers with the USCTE (Uretim Sirketi Cable Terminal End) brand.
Benefit from the advantages of being a corporate customer ...
Our Father İsmail Usta, Founder of A KALIP, graduated from Kocaeli Boys' Art School, Leveling, Metal Works with a degree in 1946.
The area from the Grand Bazaar to the Thursday market was the center of industry.
After working in a few workshops, he quickly became a master and enriched his professional knowledge with workshop experience.
1950/60
It was the period when Mecidiyeköy was full of mulberry orchards and Pofilo made profile cabinets.
He worked with Jak Kamhi as a mold master.
They built the Karaköy pier, deep drawing and plastering moulds, progressive moulds, plastic extrusion moulds.
1960/70
He produced and molded all metal and plastic parts for Ratel, Radyopanç, Timka, Grundig and many other companies.
During this period, most of the masters who trained as apprentices became factory owners or senior technical managers.
1970/80
Only mold and production were made in A KALIP workshop located across Haseki Hospital in Aksaray, Istanbul. Almost all of the molds made in this period serve the purpose of localizing the parts that could not be made in Turkey. Since A Kalıp only produces molds, workshops that produce parts quickly became factories, and its development was limited to the increase in technical capability.
1980/2000
In A Mold before the 2000 crisis, Ford Otosan imported the special welding nut mold used in the V227 project (which claims to manufacture all of its parts in Turkey) free of charge. The pre-series parts printed with this mold were tested and approved by Ford Otosan. (A.E.Goyunc/M.Karadas).
Since our company, which is a family business, does not have PSW / PFMA/16949 etc. documents, Ford directed our company to supply materials to its suppliers during the procurement process. In the next process, Coskunoz, Dostel, etc. The representatives of the companies came to make a supplier agreement. Since the supplier agreement they brought included obtaining mold technical drawings and information, this supply never took place. After this period, the Turkish automotive industry could not produce this part for 16 years and still imports it.
http://www.schmittenberg.com/produkte/a_gewindeplatten_e.asp
It continues its working life with 2nd generation fully automatic production lines, robot automation and product design, adding design and information technologies on the production experience left by our Father, who retired after 2000 and retired to farm life.
After 2000, before the Chinese products filled the market, the parts we made the molds and presses became Electric and Apparel accessories.
Capsule, snap fastener, fuse box elements, steel, copper, brass, bronze manganin etc. used in motor and other electrical components. progressive metal parts.
Smart Meter parts belonging to Basari Elektronik were produced with progressive molds and assembled with spot welding. Our own production of time and pressure adjusted spot machines were used in this production.
In the following years, parts were manufactured with reciver boxes (Set top boxes), BEKO/GOLDMASTER/REDLINE and Plasma TV back cover plastering molds and plc servo motor controlled automatic multiple punching and cutting molds between 2005/10. (BEKO)
Our company, which has been working on furniture and household appliances in the last 10 years, has dozens of patents and design registrations.
Today mainly
We produce molds and machines for the Electric-Electronic and Automotive-White Goods Sector.
All secured molds should be used for trouble-free production in fast presses.
We have been making fully automatic (Progressive) molds since the 1950s.
We are the first producers of progressive molds in Turkey, even when wire erosion and CNC machines were not available.
Radiopanç /Ratel/ ECA/Timka/Ford/ Siemens /Kaan Elektronik(Success)
Since 1947, we have been making Phosphor bronze, alloyed metals, Brass, Copper or Aluminum varying cable sections and Cable End metals, Lug molds according to standards.
who want to improve their production lines
We design and manufacture molds, production and assembly stations or lines for all Manufacturers.
A KLP Tasarım Makina Ticaret Ltd. Sti.
ESENYURT VD. 00 1215 2214
Akçaburgaz Mahallesi Alkop Sanayi Sitesi A2 Blok No:6
Equipped with modern edge technology. !!
Great company with great service and a very innovative produckt!
Mr. Ynmreq
From ADISS EM Pvt. Ltd., one of the private companies of India
Bradley Keats
One of the leading companies in the USA and Mexico, Keats Mfg.
Comments
